Modern Plastics Worldwide - July/August 2009 - dae uptlax

A Canon Communications LLC Publication
July/August 2009
THE GLOBAL PLASTICS MAGAZINE
Also in this issue:
As I See It: Hoffer Plastics readies for mold transfers
World Tour: Big tech for Serbia’s processors
World Tour: Erie automates, gets lean, succeeds
Spotlight: C&J invests in good employees
Published Continuously Since 1925
mpw.plasticstoday.com

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World Tour
32 Erie Molded Plastics has
employed specialization
and automation to grow
business and jobs.
34 China’s economy has
seemingly benefi tted from
stimulus, though the
long-term forecast is far
from certain.
38 Serbia’s processing
sector is innovating and
staying on the map,
fi nding new confi dence.
50 74 Spotlight
mpw.plasticstoday.com
38
C&J CopyIndustries
has long bet
that investing in employees
makes a difference.
CONTENTS
24 14
Also in this issue
6 Contact MPW
9 Letter from the editor
40 2009 Auxiliaries & Supplies Directory
JULY/AUGUST 2009
mpw.plasticstoday.com
30 Cover Story: Medical disposables
This month, MPW examines the medical
disposables market, which is necessarily evolving
in response to the economy, changing care
patterns, and plastics’ successful track record.
10 First Look: What MPW is reporting online
12 As I See It: Insight from industry leaders
20 Material Thoughts: The latest materials developments
24 Product Watch: New products from around the world
46 Classifieds
49 Calendar
49 Advertiser index
VOL. 86 No. 7
14 Processing Trends
Injection molding: How would like your soft foam—thick, thin, or
both? Novel slide mold makes it happen. Plus: In extrusion, coreless
winding comes of age as waste and cost bear down; Highly fi lled
compounds are gaining increasing favor via improved dispersion and
lowered costs.
25 Product Focus: Pelletizing
Without perfect pellets, a processor has little to no chance of success,
which means a number of signifi cant, recent developments are good
news for processors in lean times.
MODERN PLASTICS WORLDWIDE • JULY/AUGUST 2009 5

M P W
web exclusive
Online now at
mpw.plasticstoday.com
PC window glazing technologies continue
moving forward
I f slow and steady
wins the race, then
we can start waving
the checkered flag
now under the presumption
that polycarbonate
window
glazing—after many
years of development
still a ‘next great
thing’—is starting to
limber up and hit its
commercial stride.
Rapid prototyping slows for some,
gathers speed elsewhere
Globally, the use of additive manufacturing
(rapid prototyping and rapid manufacturing)
grew well through 2008 in many
countries, but there were some surprising
downturns including very slow
growth in the U.S. and a dramatic drop
in new installations in Japan.
Thanks to our plasticstoday.com sponsors:
Q/A equipment for
micro tools now
available
Processing of micro-sized
applications has grown
by leaps and bounds
in the past decade and
seems certain to continue
doing so. One German
manufacturer claims to
have developed the first
Q/A system for proofing
precision micro-sized
machine tooling.
Blaige & Company report:
Plastics M&A shows little sign of slowing
Blaige & Company recorded 244 plastics-industry M&A deals
worldwide in the first six months of 2009, off only 2% from the
same period in 2008. Not bad, all things considered, though more
deals lately are for distressed companies.
Sr. Group Publisher
Patrick Lundy; +1 973-808-0494
patrick.lundy@cancom.com
EDITORIAL
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6 JULY/AUGUST 2009 • MODERN PLASTICS WORLDWIDE mpw.plasticstoday.com

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EDITORIAL
An abundance of
resilience
The recent NPE was an interesting
moment in time for a number of reasons,
but principally because the show
happened to be held in the midst of an
extreme market downturn. Most exhibitors
were upbeat or at least satisfied with
the event, and I can only recall one who
quite openly said he was disappointed
with traffic to his stand (he had a pretty
good location, too).
So I boarded the plane home hoping
that times were getting better or at
least more stable, but then read a wellresearched
article on “the second wave”
of the recession that, the author predicts,
is now crashing down and will continue
doing so over the next months. The first
wave was caused by banks’ and other
financial institutions’ irrational exuberance;
this second wave is due to lending
institutions that either are not lending or
are only doing so at scurrilous rates, and
then only to the most solid customers,
thereby starving plenty of companies of
monies they may need either to invest or
to help tide them over until the recession
ends. This aversion to lending is especially
painful to privately owned, small-
mpw.plasticstoday.com
Trade shows are just a moment in
time, and thank goodness for that, as
we’d all be in sad shape if we tried to
live on three hours of sleep per night. and moldmakers has been nothing short
to-mid sized enterprises, which account
for about 90% of plastics processors
and their machinery and molding/tooling
suppliers.
I don’t think this second wave is
news to any of us; this article struck
me only because it was particularly well
researched—frighteningly so. But in talks
in the past months, and most definitely in
Chicago at NPE, people repeatedly spoke
of fighting to be “the last man standing”
so that their companies can benefit when
the good times start to roll again. And
in fact, though there have been some
closures and M&A action, so far it has
been at a much slower pace than most
assumed. During a webinar earlier this
year, one of the sharper observers of
our industry, Jeff Mengel of Plante &
Moran, predicted about 13% of North
America’s roughly 7800 processors and
moldmakers would be out of business
by year’s end, victims of the automotive
slowdown and other painful economic
forces. I spoke with Jeff during NPE and
he agreed that the resilience of processors
of amazing. The year is more than halfover
but the pace of closures has been,
thankfully, much slower than anticipated.
That is not to say that there have not
been hard measures taken, and payroll is
down at many, possibly most, companies
in this industry, the result of layoffs or
workers forced to work fewer hours (or
be paid for fewer hours, regardless of the
actual workload).
So, this is a rather long way of saying,
here’s to all of you, fighting the good
fight. You are in very good company.
Matt Defosse,
Editor-in-Chief
MODERN PLASTICS WORLDWIDE • JULY/AUGUST 2009 9

FIRST LOOK
Daily news and features at mpw.plasticstoday.com
In Brief
Berry goes WOW
Gloucester Engineering announced that
Berry Plastics will take delivery of Gloucester’s
first WOW Winder, specifically designed
for stretch-film applications and said to be
able to run hand-wrap rolls more than 50%
faster than conventional winders. More on that
winder and competitive ones in this issue’s
Processing Trends (p. 15).
Teijin exits NatureWorks
Agriculture and food major Cargill has
bought back the 50% share in NatureWorks
acquired in 2007 by Japan’s Teijin Ltd., with
Teijin saying it will focus its bioplastics’
development effort on Biofront, the highheat-resistant
bioplastic it has developed.
Nissei opens China plant
Nissei Plastic Industrial (Nagano, Japan) has
set up a manufacturing operation in China,
its first in that country, and there will start
assembling machines based on components
imported from Japan. A competitor,
Sumitomo Demag, is investing €50 million
at its two facilities in Germany, and shutting
its manufacturing facility in the U.S.
Get the global angle on industry
developments via daily updates at
mpw.plasticstoday.com.
All these stories, the magazine,
blogs, forums, and much more.
What you had to say
NPE as a springboard to a
recovery?
It is almost impossible to gauge a trade
show’s value while it is in progress, let alone
to determine its payback time, but based on
hundreds of talks and
meetings with exhibitors
at June’s NPE show in
Chicago, the decision to
exhibit in that not-inexpensive
town in what
are decidedly difficult
economic conditions
was worth it.
John Moisson, president
at distributor Jamplast
Inc.; Steve London,
COO at blowmolding
machine manufacturer
Bekum America Corp.;
; Takanori Taresawa, president of Nissei
America Inc.: these and other exhibitors
across the entire industry spectrum agreed
that the investment in NPE was a wise
one. Expectations going into the show
were low, and the last day of the event was
sparsely attended, but the show’s organizer,
The Society of the Plastics Industry (SPI),
reported that processors and others representing
nearly 19,000 companies attended
the event. Some deals were concluded at the
show floor, to include some multimillion
“To those who couldn’t make the show due to company
travel restrictions—that is certainly unfortunate. There were
many great products being offered that could potentially
show a positive return on investment had they been able
to attend and learn about these. The information is still out
there, it’ll just take more research to get it now.”
A forum visitor commenting on the NPE tradeshow; join the discussion at
plasticstoday.com/mpw.
Source: Processors’ responses to a recent
weekly poll at mpw.plasticstoday.com. Polls
change weekly; let your (digital) voice be heard.
The crowd in the South Hall of McCormick
Place during NPE2009. (Courtesy SPI)
dollar ones for film extrusion lines.
The preliminary total of visitor registrations
by the close of the show on June
26 was 44,000. While
this was about 30%
below the corresponding
number of attendees
for NPE2006, the number
of companies represented
by registrants
was down only 17%,
according to William
Carteaux, president and
CEO of SPI.
“With very difficult
economic times and
travel reductions caused
by concerns about the
H1N1 pandemic, it came as no surprise
that attendee delegations were smaller than
in 2006, but those company representatives
that did come to NPE2009 were typically
significant players with real purchasing
power,” Careaux said in a statement
released by SPI.
It remains to be seen whether the event
truly will serve as a springboard to the
industry’s recovery, or whether positive discussions
in Chicago will be washed away by
budgetary restrictions at processors.
mpw.plasticstoday.com
Polling news
10 JULY/AUGUST 2009 • MODERN PLASTICS WORLDWIDE mpw.plasticstoday.com
80%
60%
40%
20%
0%
Polling News
Is there a labor shortage of
skilled trades such as machinists,
programmers and welders?
48%
Yes, I have positions I could fill
with qualified applicants.
No, I have more employees
than I need.
We don’t use workers of
that kind.
There might be a shortage
in a few years.
26%
18%
8%

Although demand remains tepid in North America
and Europe, processors have by-and-large
depleted their stocks, and plastics suppliers have
applied the brakes to their supply chain, creating
a situation where even relatively low demand is
met with a challenging supply side.
According to spot-trading platform The Plastics
Exchange (TPE) and reporting partner, The
PetroChem Wire, suppliers were able to increase
polyethylene and polypropylene prices in June,
with many pushing for additional increases in
July and August. These actions come in a market
where volumes are still down substantially
from year-ago levels, feedstocks are on the rise,
and export interest from Asia is lifting. At press
time, linear low-density polyethylene (LLDPE)
film butene was trading at a penny premium,
while HDPE injection was about a half-cent
below blowmold grades.
In Asia, reported plastics pricing service
Polymerupdate.com, growing demand met tight
supplies and high feedstock costs, leading to
mpw.plasticstoday.com
Processors’ Choice
MPW’s November issue includes a feature on designing thinwalled
packaging. Which aspect would you prefer to see covered?
A. New material developments for thinwalled packaging
B. Machinery and molds for processing thinwalled packaging
C. Thermoforming versus injection molding for thinwalled
packaging
You can even write in your own topic.
Vote now at mpw.plasticstoday.com/survey.
Pricing Summary: Commodity resins rise
Brought to you by The Plastics Exchange and Polymerupdate.com
mpw.plasticstoday.com
price hikes in polyethylene (low- and highdensity),
polypropylene, polyvinyl chloride, and
polystyrene. Limited spot availability and rising
naphtha and ethylene helped feed the pricing
strength. An LDPE trader contacted by Polymerupdate
said that deep-sea parcels originating
from the U.S. have sold into China below $1200/
tonne CFR and helped keep Asian LDPE sellers
from pushing through greater increases. In India,
provisional anti-dumping duties on PP imports
from select producers in Singapore, Oman, and
Saudi Arabia left many PP importers “surprised
and shocked,” reported Polymerupdate.
In Europe, reported Polymerupdate, prices
moved sharply upwards for PP, PE and PS, with
PVC prices expected to rise substantially at press
time. Suppliers have slowed output at many
facilities, leaving supply tight.
Get contract and spot plastics pricing
information from TPE and Polymerupdate.
com in every issue of our e-Weekly newsletter.
Sign up free at plasticstoday.com/mpw.
Here are some of the stories you might have missed
at mpw.plasticstoday.com:
• Switch from PS and PP to PLA gets molder in the door
• Gerresheimer sells automotive molding unit to FBH Group
• Shorter hours reported at packaging processors
• Vegetable-based plasticizer garners prize, and continued investment
• Thermoformer PWP plans to build second PET recycling center
These and many more, daily, at plasticstoday.com.
Start your day right; check back often.
FIRST LOOK
Names in the news
After more than three
decades at Battenfeld,
global leader in manufacturer
of pipe and
profile extrusion lines,
Wolfgang Studener has
left the company, with
the hand at the wheel
Jürgen Arnold
now controlled by Jürgen
Arnold, who joins the firm after
serving as CEO at pump manufacturer
Sterling SIHI for six years. He also
spent some 20 years of his career in the
plastics industry at Bayer and then GE
Plastics (now Sabic).
Wolfgang Pöschl, a member of the
executive board at compound extruder
machinery manufacturer Coperion, has left
the company, with his duties to be split
between two remaining board members.
Stephen Herrmann joined extruder manufacturer
Alpha Marathon as SW U.S. sales
manager. Based in Houston, TX, he will
sell directly to film processors.
[ On the record ]
“The biggest issue underlying the
plastics industry and most all manufacturing
is that most members of
Congress have no clue what goes on
inside a factory...Manufacturers are
fed up with the presumptiveness of
535 people 875 miles away from here
thinking they have all the answers.”
Don Manzullo (R), one of four Illinois
congressmen who visited NPE2009.
“The average age in tool and die
shops [in the U.S.] today is 55, so
nationwide we expect by 2020 the
shortage of skilled workers to be
about 13 million.” Jerry Knight, executive
director, Precision Manufacturing
Institute, Meadville, PA.
“The industry makes you get big, or
you stay real, real little.” Wayne Rodrigue,
CEO of Exousia Advanced Materials,
which is ramping up scale as it commercializes
a new line of TPOs and TPVs.
MODERN PLASTICS WORLDWIDE • JULY/AUGUST 2009 11

AS I SEE IT
Staying alive means seeing the
opportunity in challenge
By Clare Goldsberry
One of the bright spots in the North
American plastics industry remains
Hoffer Plastics Corp. where, for 56 years,
the family-owned custom injection molding
company in South Elgin, IL has built
a business that has stood the test of time
and several recessions. Currently in its second
generation and led by CEO William
A. (Bill) Hoffer, the company continues
its pursuit of excellence for its customers,
employees and for the third generation.
MPW: How does Hoffer get past the bad
news so common in the industry today
and maintain a strong business?
Hoffer: Recently Plante & Moran made
a comment at an industry conference that
we have 7800 processors in North America,
and in the next 12-18 months, 1000
of those will be gone. With that, some
250,000 molds will move. This seems to
be substantiated by discussions we have
in an industry-benchmarking group that
meets quarterly. While the news lately
has been anything but good, we feel that
there’s a lot of opportunity for Hoffer,
with our extensive capabilities for tooling
transfers as well as managing those
programs. The question is how do we
take advantage of that opportunity?
If a lot of molds are going to be moving in the next 18 months, the big question
is where will they end up?
MPW: How has the company grown and
evolved in the past half-century?
Hoffer: We’ve been doing this for 56
years, and have developed a good reputation
in the industry. Bob Hoffer [Bill’s
father] built a company based on three
basic principles: putting money back into
the company, trying to improve the working
environment for the employees, and a
focus on taking care of customers; all this
while remaining financially stable and debt
free. We continue to satisfy long-standing
customers even given all the market changes
we’ve had over the decades. I think that
speaks strongly to the fact that we listen to
the customer and have met their needs and
developed these relationships.
As to Hoffer’s growth, we could have
probably expanded much more than we
did. I can remember spending many hours
in my dad’s office years ago talking about
what Gordon Lankton did [with Nypro],
but dad said he could never do what
Gordon did—get on a plane on Monday
morning and come back on Friday night.
Instead, he built a company based in South
Elgin on a focused-factory concept, with
individual plants within the same building.
We established good quality systems and
a great tool-room support system. Those
were essential to establish a position with
long-term customers: building tooling,
maintaining tooling, and moving up the
line to exceeding customer expectations.
For example, for several decades we’ve
molded nylon actuators for an aerosol
valve. We have a mold built in 1978 that
continues to run today. It has produced
parts, continues to meet customers’ quality
requirements in 2009, and has run in excess
of 35 million shots during its lifetime.
MPW: Hoffer implemented the “focusedfactory”
concept a couple of decades ago.
Is that model still working for the company
today?
Hoffer: The family management is committed
to the original vision from 1953, and to
see where we are today is a testament to the
foundation that was established. We have a
core of functional disciplines including great
tooling competency (24 full-time tool makers),
mold qualification, process validation,
and how we track and measure customer
satisfaction. The focused-factory concept
grew out of studies done by GE and DuPont
many years ago that showed the optimum
number of molding presses for a plant was
12. We built the first factory in 1960-61
and wanted to make a manufacturing cell
of approximately 12 presses. We continued
that process as we continued building and
expanding Hoffer Plastics, ending up with
eight cells we call plants. This has evolved as
the market has evolved.
Conceptually, instead of having one
big room with presses down each side as
far as you can see, we’ve developed these
focused manufacturing cells that specialize
in particular tonnage presses, customers
and markets, and we’ve stayed with this
concept. The original plants [plants 1, 2
and 3] have up to 300-ton presses. Larger
plants have 400-600-ton presses with high
ceilings and overhead cranes to handle the
larger molds.
William “Bill” Hoffer is the president and CEO of Hoffer Plastics Corp. (South
Elgin, IL). Hoffer Plastics was founded in 1953 by Robert and Helen Hoffer and
has been under the leadership of Bill Hoffer since 2005, when his father Robert
stepped down. Bill has been with the family business 38 years, as celebrated on
July 1, 2009, and has played many signifi cant roles in its success.
12 JULY/AUGUST 2009 • MODERN PLASTICS WORLDWIDE mpw.plasticstoday.com

This concept includes a finite area with
a manager and dedicated employees that
run that area. Operators are inspector
operators. They can apply to transfer to
another plant within Hoffer, but typically
they work every day with the same people,
the same manager, in the same plant. They
have a quality control system online, they
work within their plant, and they run the
same products most of the time.
MPW: What technology have you implemented
to accommodate growth?
Hoffer: We think we have continued to step
up to many of the challenges our business
presents. While maintaining our program
of updating presses—the average age of our
presses is under 10 years—we have automated
many jobs with robotics, established processing
guidelines with RJG technology, and
also looked for other ways to help maintain
the business. One of the most unique pieces
of equipment that we’ve purchased—unique
to this business—is a fluidized bed oven for
cleaning screws, barrels, and hot runner
manifolds. This was a big investment, but
with this type of custom molding, we have a
library of screws that we change often when
we do color changes or material changes.
The fluidized bed oven uses silica sand heated
to 800ºF, and cleans the residue plastic
without any intervention. This has proven
to be a much safer, more environmentally
friendly way to handle this problem. With so
many molds and so many color changes and
material changes, this has been an excellent
investment. We’re changing a screw almost
every day; all of this to meet the customer
requirements for on-time delivery.
That’s just one of the things that we’ve
implemented to be ready for the competitive
requirements of the future. With 96
presses and 400 different materials with
numerous combinations of colors, we
have a high degree of complexity. Because
of our background in packaging, closures
and aerosol parts, we have some molds
that run in 10 different colors. Complexity
is something we must deal with and this is
just one of many advantages we bring to
our customers.
MPW: How do you see the injection
molding industry today?
mpw.plasticstoday.com
Hoffer: What we see today is a troubled
supply base. A lot of people in this business—for
all the right reasons—pushed the
edge for many years. Then the perfect storm
hit our industry and there are many people
deciding they can’t do this any more, and
will either sell or go out of business.
But it comes down to who will be
here for the customers in the long term.
Executive Q&A with Bill Hoffer
We have a renewed focus on the markets
we serve and even some new ones, to see
where we can become a major factor with
these customers, both old and new. MPW
mpw.plasticstoday.com
To read the rest of our interview with Bill
Hoffer, click on the “As I See It” tab on
our home page.
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MODERN PLASTICS WORLDWIDE • JULY/AUGUST 2009 13

PROCESSING
TECHNOLOGY
PROCESSING TRENDS: p. 14
In film extrusion, coreless winding’s
time has arrived; highly filled
compounds increase dispersion,
lower cost; and much more.
MATERIAL THOUGHTS: p. 20
New class of TPO claims to offer
better performance without the
traditional oils and plasticizers;
Alathon film line gets new grades
of MMW high-density polyethylene;
new high-flow TPV promises
“cushion-like” indentation; carbon
fibers teamed with PPA, PPS, and
PEEK to create “super structural
compounds;” and more.
PRODUCT WATCH: p. 24
Product Focus: Pelletizing. New
developments boost bottom line.
Plus: New screw allows entire
length of extrusion unit to process
material; no marking or swarf
claimed for PS pipette line; Jomar
marks 40th anniversary with new
line; and much more.
14 JULY/AUGUST 2009 • MODERN PLASTICS WORLDWIDE
PROCESSING TRENDS
Novel mold lets soft foam
be thick, thin, or both
By Matt Defosse
In what is being claimed as an injection
molding first, a slide-table mold
developed by Swiss moldmaker Georg
Kaufmann Formenbau AG (Busslingen)
enables processors to vary the thickness
of a layer of soft-touch foam exactly
where it is required on a part, via the
mold’s geometry. ‘Varysoft’ is the name
the moldmaker has affixed to its novel
system.
The company is well known in moldmaking,
especially for molds used to
process door panels and other automotive
interior components. For its newest
feat, the company built a mold with two
cavities, one for the conventional injection
molding of a supporting structure
Slide-table mold enables proces-
sors to vary the thickness of a layer
of soft-touch foam exactly where it
is required on a part, via the mold’s
geometry. ‘Varysoft’ is the name the
moldmaker has affixed to its novel
and elegant system.
(typically polypropylene) and one for
preforming of a decorative material—
film, fabric, or imitation leather. For
the foam layer, the machine needs either
an additional injection unit for expandable
thermoplastic elastomer (TPE) or
a polyurethane (PUR) processing unit
with PUR mixing head.
Kaufmann molded this business card holder to demonstrate its new back injection
molding system. The 0.2-mm thick aluminum film on the top, visible part of the
holder was embossed with the logo during back injection molding; the reverse
side of the top part is provided with integrally molded clips for attachment to the
bottom part.
mpw.plasticstoday.com

PROCESSING
TECHNOLOGY
Let the processing begin
How are parts formed? First the
pre-cut decorative material is
placed in the second cavity of the
open mold and fixed in place. The
mold closes and the decorative
material is preformed, while in the
first cavity the polypropylene (PP)
is molded and then cooled. When
the mold opens, the PP supporting
structure remains in the moving
mold half and the pre-formed
decorative material remains in the
stationary mold half.
The two halves of the open
mold are then repositioned by
means of a sliding table so that the
PP supporting structure and the
preformed decorative material face
each other. The mold then closes but a
gap remains between the halves. This
gap represents the thickness of the foam
layer and is determined by the geometry
of the second cavity; it is deeper than
the geometry of the first cavity by a
distance equal to the desired thickness
of the foam.
This gap is then filled with foam,
with either expandable TPE injected into
the gap via a gating system and diverter
mpw.plasticstoday.com
PROCESSING TRENDS
Here, shown in a 2-injection unit configuration, the
Varysoft slide-table mold lets processors get softtouch
foam exactly where it is needed.
mounted on top of the mold, or via the
PUR mixing head, docked against the
underside of the mold. Once foaming is
complete, parts can be de-molded and
any surplus decorative material can be
trimmed.
In another decorative development,
Kaufmann also says it can make injection
molds suitable for back injection
molding of metal films. Such films could
be thick enough to give the feel and
look of a genuine metal surface,
more so than with electroplating,
but without requiring a secondary
operation.
Here again, the process is deceptively
simple. The metal film is
placed and held in a mold in essentially
the same way as any other
decorative surface would be for
back injection molding.
With this development, any surface
structures machined into the
walls of the cavity (logos, for example,
or other decorative elements)
can be transferred to the molded
part (see photo, previous page).
While the mold is closed after injection,
an integrated punching tool
separates surplus film from the
molded part, but leaves the edges of the
film wrapped around the part to produce
a smooth edge.
Kaufmann says it already has formed
parts using aluminum and stainless steel
films and is testing other materials. The
moldmaker worked with the university
in Rappperswil, Switzerland on development
of the coupling agent necessary for
a reliable metal-plastic bond.
Coreless winding cuts transport costs, pleases Walmart
By Robert Colvin
New fi lm extrusion lines increasingly
include winding technologies
that either employ thin-wall paperboard
cores or even eliminate cores
altogether. Processors are set to
benefi t from the savings.
According to Dave Finnemore, VP sales
EMEA at Gloucester Engineering (Vienna,
Austria), the technology’s introduction
is being pushed by environmental
sensibilities. “The main aims behind
developing [film] products with thinner
cardboard cores or even with no core
at all are reducing costs or removing
the need for management and disposal
of the used cores, reducing waste taxes,
eliminating shipping and storage costs
by optimizing film meterage on a pallet,
and lowering production
costs,” he says.
Finnemore says
an estimated 350 million
cardboard cores
are disposed of annually
in Europe, Russia/
CIS countries, and the
Middle East. While some
Central European core
suppliers offer collection
systems for recycling,
in other regions such
schemes don’t exist. He
says global multinationals
such as Walmart, Coco-Cola, P&G,
and the Carrefour group are implementing
environmental policies for waste
reduction that foresee not accepting
Easycoreless shafts comprise up to 250 expanding and
contracting parts to produce stretch film without the
need for cores. Thin cores and standard cores can also
be produced.
hand- and machine-stretch pallet-wrap
film if the retailers have to dispose of
paperboard cores.
While resin costs for cast stretch-film
MODERN PLASTICS WORLDWIDE • JULY/AUGUST 2009 15

PROCESSING
TECHNOLOGY
production typically represent 80% of
total cost, processors of course always
are on the outlook for other ways to
save, and cores represent one of the latest
areas of consideration. Finnemore
says in an average in-line handwrap
production of four 17-μm film reels of
300 m/reel, processors generally use a
paper core with a wall thickness of 5
mm. This represents €0.15 or 23.3% of
the total conversion cost. Machine film
conversion costs of four reels of 23-μm
film running 1500m, and assuming a
core with wall thickness of 11 mm, will
represent an average core cost of €0.42.
But the question remains whether
cast-film extrusion operations will accept
new solutions such as handwrap cores
of only 1-2 mm in wall thickness, and
machine film with core wall thickness of
only 5 mm or even coreless, Finnemore
says. “Reduction in core weight or elimination
will ultimately reduce the overall
cost/kg of film transportation. Walmart
CEO Lee Scott reported back in 2007
that the company was pressing vendors
to go more green, and both handwrap
and machine wrap were target areas.”
Suppliers [who deliver to Walmart] are
being asked to cut their packaging by
5% by 2013.
During this year’s Plast ’09 show in
Milan, Gabriele Caccia, managing
director of Syncro, introduced the
company’s latest co-development for
coreless stretch wrap winding, Easycoreless,
pictured here at the stand.
PROCESSING TRENDS
Finnemore says generally 8360 reels
of hand wrap (5-mm wall cores at 300g)
fit into an average truck. Using 2-inch
cores with a 2-mm wall thickness
at 115g, the core
weight savings represents
1546 kg per
22 tonnes of film,
a potential reduction
of 7%. Without
cores, an additional
250,800m of film could fit
in each truck representing a
€0.005/kg reduction in film
transport costs.
With machine wrap, by using 3-inch
cores with a 5-mm wall thickness
at 450g compared to 11mm wall
cores at 1.1 kg, the core weight
savings is 858 kg/23 tonnes’ film
load, where 1320 reels fit into a truck.
This represents a 3.67% reduction of
transportation weight. The thinner cores
would allow 132,000m more film per
truck, for a transport cost savings of
€0.003/kg.
Finnemore sees thin cores being an
intermediary step and the ultimate goal is
to produce reels of stretch wrap without
the need for any cores. His company,
along with competitors Colines (Nibbia,
Italy), Dolci Extrusion (Milan, Italy), and
SML (Lenzing, Austria) are all working
together with Syncro (Busto Arsizio,
Italy) to develop coreless
winding that could
be used on existing and
new winding equipment.
Gabriele Caccia, managing
director of Syncro,
says the past two years
of R&D has produced
its latest development,
the patented Easycoreless
technology introduced
at the Plast 09 show in
Milan, which has already been tested for
what soon will be offered by the partners
on new equipment and retrofitting on
installed machines.
The proprietary rotating shafts have up
to 250 expanding and contracting parts
to wind, then deliver a wound film roll
from the shaft; they are able to convert to
winding with thin-walled cores or regular
Canadian machine maker Cooper
Machine & Tool offers this turret winder
for tear-off bags.
thickness cores as well, Caccia says.
Development proceeds on the other side
of the Atlantic as well, and at last month’s
NPE, Canada-based Cooper Machine &
Tool (Concord, ON) was talking about
its turret coreless winder. The winder
is said to be fully automatic and winds
coreless rolls of perforated tear-off bags
Finnemore says in an average in-line
handwrap production of four 17-μm
fi lm reels of 300 m/reel, processors
generally use a paper core with a
wall thickness of 5 mm. This represents
€0.15 or 23.3% of the total
conversion cost.
at up to 20 cycles/minute, claimed to
double traditional coreless winder speeds.
Operators can adjust the winding width
individually on both sides and on the
fly. Also, NO.EL Industrial Automation
(San Pietro Mosezzo, Italy), as reported
in our August 2008 issue (p. 41), will
import its coreless rewinding equipment
to North America.
16 JULY/AUGUST 2009 • MODERN PLASTICS WORLDWIDE mpw.plasticstoday.com

PROCESSING
TECHNOLOGY
Higher loads bring
processing advantages
By Robert Colvin
Reinforcing agents provide physical properties that can’t
be achieved in resins alone.
Many processors are looking to highly filled compounds to
help them improve dispersion and lower overall costs, says
Stanley Broadhead, senior sales engineer at equipment maker
Farrel (Ansonia, CT).
Oliver Eitel, business segment manager engineering plastics
at equipment maker Coperion (ex-Werner & Pfleiderer; Stuttgart,
Germany) says the motivation today to use, for example,
highly filled calcium carbonate (CaCO 3 ) compounds is that
Coperion’s new compounding line layout for highly filled,
calcium carbonate-filled polymers permits easier handling
and more filler content, says the company.
the particle-size distribution can be chosen, plus the filler is
non-toxic, food safe, offers good organoleptic properties,
and because of its spherical shape and low hardness it results
in low wear and tear on processing equipment. High filler
content naturally results in lowering polymer costs, but also
provides a powder-free shop floor.
Eitel says such fillers increase the modulus of elasticity
of the matrix material, improve antiblock behavior, result
in less shrinkage during cooling and provide higher thermal
conductivity compared to the polymer alone. This last feature
results in quicker temperature equalization and faster processing
speed.
He also says a 50% CaCO 3 content in injection molding
applications can result in a shorter cooling cycle by half, and
20% filler content in blown-film extrusion can give a 20%
higher haul-off speed. Farrel’s Broadhead says both injection
molders and film extrusion processors generally opt for highly
filled concentrates, with loadings up to 85%, to get both
desired opacity and lower unit costs.
mpw.plasticstoday.com
© 2009 PerkinElmer, Inc. 400161_02. All trademarks or registered trademarks are the property of PerkinElmer, Inc. and/or its subsidiaries.
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MODERN PLASTICS WORLDWIDE • JULY/AUGUST 2009 17

PROCESSING
TECHNOLOGY
Traditionally, highly filled
polyolefin compounds have been
produced by repeated loading via
several feed positions on the compounding
extruder, followed by
mixing up to three or more times.
This, says Eitel, is done because
CaCO 3 , with a bulk density of
600-800 kg/m 3 , tends to be sticky
and build bridges, often creating
headaches for an operator. To
overcome such problems, agitators
are often used, hoppers are
designed with special geometry to
improve material drop, or flexible
walls can be incorporated that
can shake up the filler to break up
bridging.
Coperion says experience has shown,
in its latest line design for such applications,
that, during refilling of loss-inweight
feeders using slide, butterfly, or
rotary valves, the valve itself needs to
be installed closer to the feeder hopper
so that it can react quickly in shutting
PROCESSING TRENDS
Specific energy input drops, and pressure increases,
as filler content increases: that has been Coperion’s
experience with its new line for highly filled compounds.
off. This is necessary to avoid overfilling.
The company developed a new layout
for its ZSK compounder by mounting
the CaCO 3 feeder directly above the
unit’s co-rotating twin-screw side feeder,
ZSB. This setup, says Eitel, results in the
need for only two feeders and two refill
hoppers for the CaCO 3 . It also provides
Bioplastic barrier fi lm matches EVOH, PA
By Matt Defosse
Blown- and cast-fi lm extrusion
line manufacturer Colines (with
manufacturing sites in Novara and
Varese, Italy) says recent testing
proves that PLA/PVOH fi lms extruded
on the company’s cast- and
blown-fi lm lines with structures of
up to 7 layers and with thicknesses
from 50 to 90 μm offer sufficient
oxygen barrier properties, while
also maintaining top optical
performance, as shown by the
values of haze and gloss and the
fi lm’s printability.
Colines officials say the lines have been
modified so as to render the same performance
as lines running barrier films
containing polyamide or ethylene vinyl
alcohol (EVOH) barrier materials, with
no loss in line productivity.
The combined structure of polylactic
acid (PLA), based on plant starches,
and polyvinyl alcohol (PVOH, a biodegradable,
water-soluble polymer) in
these barrier films offers sufficient gas
barrier performance to prove them
suitable for use in applications such
as packaging of meat and fish, and, in
particular, fruit and vegetables.
The company invited interested processors
to its open house from July
27-31, 2009, and requested email preregistration
at marketing@colines.it.
Also during that open house the company
planned to run a line extruding
breathable film with an in-line double
mono-orienting unit (MDO). The line,
which can extrude breathable film in
PE and in PP, has a useful width of
2200 mm and the double-MDO unit
offers orientation of up to 600% (2 x
300%). It will feature post-stretching
embossing and comes outfitted with a
thickness control before and after the
a longer mixing section for the
filler, better dispersion, and higher
output. With the increase by percentage
of the compound/weight
of filler, the discharge pressure in
bar is increased while the specific
energy input measured in kWh/kg
is reduced.
Farrel takes a different approach
to compounding highly filled concentrates.
Its FCM (Farrel Continuous
Mixer) operates on the principle
that the material is exposed
to a variable mixing intensity in
the form of shear stress and strain
developed between the rotor tips
and chamber wall, as well as melt
blending by the kneading action between
the rotors. “The measure of dispersion
through either visual examination or
filter pressure values are as good or better
than those achieved with twin-screw
extruders,” says Broadhead. “Besides
that, we get the added benefit of lower
energy costs.”
stretching, with automatic adjustment
according to the set target. Trim is
recovered directly and pelletized.
It also includes the firm’s Fast
AdJUST (Elav) system for micrometric
adjustments of the stretching parameters
of the line. Colines reports it
has worked with this system and is
able to offer processors the option
of live monitoring of the data relative
to the extrusion lines. The report
system lets a user track consumption
data (energy and raw material), various
trends (throughout and machine data),
recipes, management of the production
orders, ordinary and preventive maintenance,
and diagnostics. The acquisition
and processing of the data are
incorporated directly in the automation
system, with the data then able to
be sent to computers on the other side
of a facility or even further afield.
18 JULY/AUGUST 2009 • MODERN PLASTICS WORLDWIDE mpw.plasticstoday.com

PROCESSING
TECHNOLOGY
Johnson Controls applies
PP fi lm to claim auto awards;
KM takes home three
By Tony Deligio
The Mercedes-Benz E-Class door panel and rear-side
panel of the new Mini Convertible earned Johnson
Controls GmbH (Burscheid, Germany) two interior-system
prizes at the Society of Plastics Engineers (SPE) Central
Europe’s 12th Automotive Div. Awards.
The door panel earned marks for overall quality and a scratchresistant
map pocket, with the rear side panel also offering a
scratch-resistant surface. The new Mercedes door panels are
10% lighter than the previous model and represent a full subassembly
with map pocket, center panel, armrest, and upper trim
panel. Johnson Controls also integrated ambient lighting above
the door’s center panels and in the door handles, with sun shades
built into the rear door. The company says this allowed it to
improve the window cover in a minimum of space.
Johnson Controls opted for what it calls polypropylene (PP)
thin film for a variable degree of glossiness that can match other
components’ finish. A Johnson Controls representative told
MPW that the technology, which it presented for the first time at
the 2007 Frankfurt Motor Show before launching it at the end of
last year, was used for the map pocket of the E-Class door panel
and in the rear side panel of the new Mini Convertible.
The PP thin film consists of a composite foil constructed from
several—primarily PP—layers, which are manufactured in a
direct mold-behind process. According to Johnson Controls, the
film is extruded by its partner Nordenia, and then preformed at
Johnson Controls’ production plant. The preformed film is then
back-injection molded and inmold grained.
The process allows all types of PP to be used as substrates,
even fiberglass-reinforced and recycled materials. Johnson Controls
says that unlike painted component surfaces, the foils are
not easily scratched and since their gloss level can also be varied,
they can more easily match the finish of adjacent components.
Depending on the design, a one- or two-step production process
can be applied, with a two-step system used for deep-molded
products, like the map pockets in the doors.
KraussMaffei’s (KM; Munich) machinery was utilized in three
award-winning parts. A support element for the louvered grille
of the Mercedes-Benz CLS Coupe took the top prize in the Body
Exterior category, applying a metallic effect without extra painting.
In the same category, KM won for a bodywork component
on a forage harvester that used KM reaction machinery. In the
Powertrain category, a glass-fiber-reinforced roll restrictor for the
Opel Insignia was recognized. MPW
mpw.plasticstoday.com
You can find pictures of these winning parts online at www.
plasticstoday.com/articles/johnson-controls-applies-pp-film.
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MODERN PLASTICS WORLDWIDE • JULY/AUGUST 2009 19

PROCESSING TECHNOLOGY
MATERIAL THOUGHTS
Technology drives new
class of elastomers
Eliminating the oils and plasticizers typically used to soften the
materials, a new class of elastomers claims to offer higher performance
for longer durations at more temperature extremes.
Wayne Rodrigue, CEO Exousia Advanced Materials, told
MPW his company’s RPA thermoplastic olefin (TPO) also
eliminates exposure to hydrogen peroxide as a manufacturing
step with a proprietary process that results in covalent bonding
between the crosslinked rubber and its olefin matrix.
Coming to market with 14 formulations, Exousia has
spent the last two years developing commercial applications
for the technology and proving its viability. This work
included testing with General Motors to the have the resin
validated for use in automotive components. Exousia says
theses tests proved the material dimensionally stable from
-40°F to 140°F. While oils and plasticizers can bleach out
New HDPE, PP grades
boost fi lm properties
The latest additions to the Alathon
family of film resins include two new
medium-molecular-weight (MMW), highdensity
polyethylene (HDPE) materials,
which promise moisture barrier, low
gels, and excellent organoleptic properties.
Alathon M6010 and Alathon M5010
have improved moisture barrier for dryfood
packaging applications like cereal,
snack crackers, and cake-mix box liners.
An MI homopolymer, LyondellBasell says
lab tests have shown that Alathon M6010
increased moisture barrier vs. benchmark
grades by approximately 30% without
affecting processability, tear, and impact.
The material also offers oxygen barrier.
Alathon M5010 is a 1 MI copolymer
resin designed to improve toughness for a
variety of films, including mono- and multilayer
structures. LyondellBasell says the tear
performance of film made from the material
has been increased 20%, while high-speed
puncture resistance was boosted by 40%.
Alathon M6010 and Alathon M5010 are
currently manufactured in the U.S. and
available for export.
In blown polypropylene (PP) films,
LyondellBasell has launched a grade based
on its proprietary Catalloy technology
that offers a combination of transparency
and impact, puncture, and tear resistance.
Adflex 7492 XCP has a 13% haze value
at a film thickness of 30 μm, offering clarity
while maintaining softness and processing
performance. LyondellBasell says the
product fills a need for a transparent blown
PP that maintains mechanical properties,
bubble stability, and throughput. The company
believes applications could range from
consumer and industrial packaging to agricultural
and industrial films, and it’s working
to develop new blown-film applications
where PP grades previously fell short.
LyondellBasell’s new Adflex 7492 XCP grade of
PP for blown film combines transparency with
resistance to impact, puncture, and tears.
of a part like a dashboard over time, resulting in fogging of
the windshield and a brittle, discolored instrument panel,
Rodrigue says Exousia materials had zero migration or
durometer change.
Among the truly novel characteristics of the material,
according to Rodrigue, is that it actually gets tougher the
colder it gets; when melted, it exhibits thixotropic properties,
flowing like water; and it can be rigid or soft, with a durometer
range from 55 to 95 Shore A. Exousia says the product
is suitable for all major plastic converting technologies, save
rotational molding, and it sees it as a viable replacement to
engineering plastics like ABS (offering more impact), and
nylon, being hydrophilic as opposed to hygroscopic.
Exousia Advanced Materials Inc., Sugar Land, TX, U.S.A.;
+1 281-313-2333; www.exousiacorp.com
The company has conducted what it
calls promising tests where Adflex was
used as the core layer in a co-extruded
film with fractional melt-flow-rate LDPE.
The finished product maintained clarity
when clarified PP skin layers were used.
LyondellBasell says customers needing
greater mechanical properties could apply
(metallocene) mLLDPE skin layers with a
Adflex 7492 XCP core.
LyondellBasell, Rotterdam, the Netherlands;
www.lyondellbasell.com
TPV gives auto interiors a
softer touch
Promising cushion-like indentation that’s
associated with foamed structures, a
new high-flow thermoplastic vulcanizate
(TPV) also offers cost-reduction
opportunities and good surface qualities
for automotive interiors. ExxonMobil
Chemical’s Santoprene TPV 8211-85
M350 reportedly provides low and stable
gloss level; high scratch and mar
resistance; good abrasion and chemical
resistance; and low fogging and odor
emission. The elastomer is colorable and
can be used for door panels, center
consoles, lower instrument panels, back
cover of seats, and B and C pillars.
To achieve “comfort touch,” Santoprene
TPV M350 can be processed using two-
20 JULY/AUGUST 2009 • MODERN PLASTICS WORLDWIDE mpw.plasticstoday.com

PROCESSING TECHNOLOGY
ExxonMobil Chemical’s Santoprene TPV M350
provides what the company calls “comfort
touch,” and good surface qualities for automotive
interiors.
component injection molding or monosandwich
molding onto a rigid polypropylene
substrate for an unfoamed structure that
does not indent. Either way, ExxonMobil
Chemical says the result is an over-molded
TPV skin with a soft touch. A thermoplastic,
the TPV also has what the company
calls “sustainability opportunities” because
less labor and time are required for production,
with reduced scrap and improved
recycling.
ExxonMobil Chemical Company, Houston,
TX, U.S.A.; +1 281-870-6000;
www.santoprene.com
Compounder teams
carbon fi bers with PPS,
PPA, and PEEK
Specialty compounder LATI Industria
Termoplastici SpA (Vedano Olona, Italy)
has created a new range of injection moldable
“super structural compounds,” pairing
high-temperature, high-performance
engineering thermoplastics polyphenylenesulphide
(PPS), polyphthalamide (PPA),
and polyetheretherketone (PEEK), with
high-modulus carbon-fiber yarns. The
result: the HM (High Modulus) family
of compounds with 40% carbon-fiber
loading for what LATI calls dramatically
higher elastic modulus.
In the development of the compounds—Larton
K/40 HM (PPS),
Laramid D K/40 HM (PPA), and Larpeek
10 K/40 HM (PEEK)—LATI weighed a
mpw.plasticstoday.com
variety of resins, fibers, and compounding
technologies. High-tenacity choppedstrand
carbon fibers are traditionally
applied in thermoplastic compounding
to increase elastic modulus and load
at break without making the materials
brittle. LATI chose to experiment with
high-modulus carbon-fiber yarns, saying
the HM yarns show an elastic modulus
that is almost twice that of HT grades.
LATI also considered the high shear
stress and pressure within a compounding
extruder that can break up fibers,
ultimately affecting the strength they
can impart to the composite. After several
trials, LATI technicians altered the
extrusion parameters and optimized
machine layout, specifically addressing
the carbon-fiber feeding position along
the extruder barrel. In terms of parameters,
LATI says the speed and profile of
the plasticization screw have also been
optimized.
Throught the trials, LATI found it
needed to deal with fiber-bundle buildup
occurring during extrusion and molding,
with the bundles hindering melt flow
and leading to the carbonization of the
polymer, machine jamming, and defective
parts. HM fibers were added up to
45% by weight, and the melt’s viscosity
was closely controlled to avoid poor
molding and material degradation due to
friction and shear. LATI was also careful
to ensure uniform distribution of carbon
fibers in the matrix.
Using ISO-R-527 tensile tests, the
compounder determined the HM materials
achieved tensile strengths above
40,000 MPa, with the PPS-based grade
New developments
reaching 49,000 MPa. By comparison,
LATI says a polyamide 6/6 reinforced
50% with glass fibers, is three times
“softer” than the best HM grade. In
terms of load at break, HM compounds
offer up to 280 MPa (tensile, as per ISO-
R-527) for the PPA-based grade. LATI
says competitive industrial structural
compounds featuring 50-60% glass-fiber
loading achieve around 220 MPa with a
much higher density.
LATI Industria Termoplastici SpA, Vedano
Olona, Italy; +39 0332-409111; www.lati.com
Additives bring tastes,
aromas to plastics
Plastic applications requiring custom taste
and scent enhancements can look to a new
alliance between compounder A. Schulman
Inc. (Akron, OH) and Add the Flavor
LLC (New York), which hopes to commercialize
its Polyflav product as a masterbatch
or additive. Chuck Hampton, A.
Schulman’s North American masterbatch
business manager, sees a variety of end
markets for the technology, telling MPW,
“We envision applications in virtually any
plastic part that may come in contact with
the mouth,” Hampton said. “Items such
as mouthguards, toothbrushes, flossing
devices, waterbottle spouts, etc., have been
discussed.” A. Schulman will add them
to its Polybatch line of specialty additive
masterbatches.
Polyflav comes in two series, S and O,
with both reported to provide long-lasting
flavor. “S” offers a “strong” scent with a
“subtle” taste, according to A. Schulman,
while the “O” or “Optimized” series provides
both strong scent and taste.
Hampton said the materials are FDA
recognized, and several customers are in
sampling and scale-up. The company
expects commercial applications to be in
the field over the next three to six months.
“Now that we have announced to the
public,” Hampton said, “we expect the
pace of projects to heat up as molders seek
to be first to offer a product utilizing this
innovative technology.”
Current flavors include mint, raspberry,
grape, lemon, chocolate, and orange.
A. Schulman Inc., Akron, OH, U.S.A.;
+1 330-666-3751; www.aschulman.com
MODERN PLASTICS WORLDWIDE • JULY/AUGUST 2009 21

PROCESSING TECHNOLOGY
MATERIAL THOUGHTS
ADDITIVES/FILLERS
Impact modifi ers help
processors cut costs
The latest development in acrylic impact
modifiers for rigid vinyl window and door
profiles from Arkema, Durastrength 360,
is said to reduce by up to 15% the amount
of acrylic modifiers in formulations. This
range of “composite” impact additives has
a high elastomer content and can reduce
plate-out during extrusion. Less plate-out
Durastrength 360 composite impact modifiers aid
PVC profile extrusion.
means die head and extruder can run
longer between maintenance. Arkema says
the material also improves profile production
speed. The impact additives have
been marketed for several months and are
finding particular demand from Eastern
European countries, says the company.
Arkema, Colombes Cedex, France;
+33 1-4900-8080; www.arkema.com
Permanent antistatic
effect enhances
Entira brand antistat from DuPont is a
resin modifier that is claimed to provide
good permanent antistatic properties
and high moisture permeability in polyolefins.
It can be used for blowmolded
polypropylene and polyethylene containers.
Grade AS MK400, in 2-layer
blowmolded bottles of approximately
1-mm wall thickness, provides immediate
and long-life antistatic effect without
blooming. It prevents dust and dirt pick-
up, has no interaction with printing or
labeling, and is compatible with polyolefins
and ethylene copolymers.
DuPont de Nemours International, Geneva,
Switzerland; +41 22-717-6643;
www.packaging.dupont.com
MASTERBATCHES
Thinner white packaging
is in higher demand today
In response to the demand for more costeffective
coloring of white thin-wall polyester
packaging, masterbatcher Colour
Tone has developed a PET-based white
masterbatch containing 70% titanium
dioxide (TiO 2 ), which the company
says is about 20% more pigment than
conventional products on the market.
Company managing director Tony
Gaulkroger says this product should be
of particular interest to processors in
both bottle and thermoformed packaging
sectors. The lighter packaging is
less costly to transport and creates less
waste to recyc le. However, cutting wall
thickness reduces opacity, which is particularly
critical in white packaging, he
says. The proprietary means of achieving
the 70% TiO 2 content is due to formulation,
processing technology, and pigment
Typical applications for Colour Tone Masterbatch’s
70% TiO 2 content PET-based material are thinwalled
bottles and thermoformable sheet for
beverage and food packaging.
New developments
dispersion techniques coupled with customdesigned
downstream equipment.
Colour Tone Masterbatch Ltd.,
Bedwas, Wales; +44 2920-888-910;
www.colourtone-masterbatch.co.uk
Wire/cable applications
take on new hues
A line of melt-processable fluoropolymer
(MPFP) color masterbatches for the wireand-cable
sector from engineering thermoplastic
compounder RTP promises
ease of processing and good color exactness
in plenum-space jacketing materials.
Available in 10 common wire-and-cable
industry color-coding formulations, they
match Munsell and RAL standards.
RTP’s MPFP product line of color masterbatches
offers 10 common wire-and-cable sector colors.
These color masterbatches are initially
available in fluorinated ethylene propylene
(FEP) and polyvinylidene fluoride
(PVdF). Let-down ratios are about 3%,
says the company, and they provide
good dispersion. They also maintain
the inherent flame retardancy and low
smoke development of the fluoropolymer.
“Historically, fluoropolymers have
been difficult to modify,” says Jean Sirois,
general manager-RTP Color. “Because of
their corrosive nature, RTP has dedicated
manufacturing equipment used solely for
processing MPFP products.”
RTP Company, Winona, MN, U.S.A.;
+1 507-454-6900; www.rtpcompany.com
22 JULY/AUGUST 2009 • MODERN PLASTICS WORLDWIDE mpw.plasticstoday.com

Attend the World’s Leading Automotive
Composites Forum
The Automotive and Composites Divisions of the Society of Plastics
Engineers (SPE) International invite you to attend the 9 th -annual SPE
Automotive Composites Conference and Exhibition (ACCE),
September 15-16, 2009. The show – which has become the
world’s leading automotive composites forum – will feature technical
paper sessions, panel discussions, keynote speakers, networking
receptions, & exhibits highlighting advances in materials, processes,
and applications technologies for both thermoset and thermoplastic
composites in a wide variety of ground-transportation applications.
Be a Part of an Engaged, Global Audience
The SPE ACCE typically draws over 400 attendees from 14 countries on
4 continents who are interested in learning about the latest composites
technologies. Fully a third of attendees work for an automotive, heavy
truck, agricultural / off-road equipment, or aerospace OEM, and roughly
a fifth work for a tier integrator. Few conferences of any size can offer
such an engaged, global audience vitally interested in hearing the latest
composites advances.
Showcase Your Products & Services
with Exhibit & Sponsorship Opportunities
A variety of sponsorship packages – including displays, conference giveaways,
advertising and publicity, signage, tickets, and networking receptions
– are available. Companies interested in showcasing their products
and/or services at the SPE ACCE should contact Teri Chouinard of
Intuit Group at teri@intuitgroup.com.
’09 ACCE Early-Bird Sponsors
CLICK mpw.plasticstoday.com/infolink
Please Attend
Exhibit & Sponsorship
Opportunities
For More Information
For more information on the Automotive
Composites Conference, or to register
for this important event, visit the
SPE Automotive Division website at
www.speautomotive.com; or contact
Pat Levine at +1.248.244.8993;
or send an e-mail to
acce-registration@speautomotive.com;
or write SPE Automotive Division,
1800 Crooks Road, Suite A, Troy MI
48084, USA.
MSU Management Education Center
811 W. Square Lake Rd., Troy, MI USA

PROCESSING TECHNOLOGY
PRODUCT WATCH
EXTRUSION
Wavin on board for new
KM screw design
Pipe extrusion processor Wavin helped develop and field-test a new
range of 36D twin-screw, single-venting extruders for processing
of PVC pipe, and these new machines are now being offered to the
broader processing market by extruder manufacturer KraussMaffei
Berstorff.
They are outfitted with what KraussMaffei is calling its HPG
(High Performance Geometry) screw concept, with which the
entire 36 L/D length of the processing unit is used to optimize
plasticizing and homogenizing of PVC. Atmospheric venting has
been eliminated. Throughput is up to 10% higher than with
double-venting extruders, according to KM.
A longer metering zone means the machine
can better build pressure and keep
control of the melt temperature over
the whole output zone. The longer
mixing zone also improves dispersal
of additives and blowing agents in the
melt.
With only one venting zone, the whole length of KraussMaffei, Munich, Germany;
the unit can be used to process material. +49 89-88-990; www.kraussmaffei.com
Tools good for four stripes
An extruder tool
from this manufacturer
of precisionextrusion
tooling
for cable, hose,
pipe, and profiles
has introduced
a striping
attachment that
allows the co-extrusion
The B&H striping attachment offers
multiple options to wire and cable
processors.
of a single, dual, triple or ‘quad’ stripe. The attachment installs between the die
holder and barrel body. It is said to be compatible with all adjustable center crossheads
and in-line dies used for insulating wire and jacketing cable. The attachment
allows the stripe to be embedded in a tube or jacket, or extruded on the outside.
Attachments are available for low-temperature and high-temperature insulated
wire and jacketed cable applications. Processors can choose a stand-alone striping
attachment or opt for a new assembly that includes the attachment. An extendedrange
core tube can be supplied where added length is needed.
Also new from the company is a tip removal wrench for use with its in-line spider
dies. The tool was designed to reduce the time, effort, and risk involved with
changeovers and to lengthen tool service life. It enables operators to access the tip
even when space is tight, without creating dead spots, or otherwise damaging the
flow path or assembly parts.
B&H Tool Company, San Marcos, CA, U.S.A.; +1 760-471-8949; www.bhtool.com
Extrusion line targeted
at PS pipettes
New from Boston Matthews is an extrusion
line designed specifically for the production of
polystyrene pipette tubes. The manufacturer
says the line is capable of extruding, sizing,
drying, and accurately cutting PS tubes without
marking or swarf, no small claim considering
PS’s sticky nature. A direct-drive on
Sticky PS pipettes are no
problem for this line.
the extruder yields clean, brushless operation.
The machine was designed with clean- or
greyroom processing in mind, with easy-clean
surfaces and easy access to all areas. Typical
tube sizes range from 1-25-ml capacity. All
tubes are extruded and cut to length in-line
at up to 30 tubes per minute. The firm’s ‘PS
Tube Cutter’ can be automatically synchronized
for more accurate cutting.
Boston Matthews, Worcester, England;
+44 1905-763101;
www.boston-matthews.co.uk
Automatic strap coilers
A fully automatic coiling range that coils
and straps flexible plastic pipe up to 180
mm in diameter is now available from
Pipe Coil Technology Ltd. Pipe processors
can coil and package their pipe by fully
automating a process that in the past often
required high labor levels. This machine
range automates the whole coiling process
from the point the pipe leaves the extrusion
line to the removal of the completed coil.
Pipe Coil Technology Ltd., Wallsend,
Tyne & Wear, England; +44 191-295-9910;
www.pipecoil.co.uk
24 JULY/AUGUST 2009 • MODERN PLASTICS WORLDWIDE mpw.plasticstoday.com

PROCESSING TECHNOLOGY
Product Focus: Pelletizing
It all starts with the pellet
Well, maybe it starts with the idea, but without perfect pellets a
processor has little to no chance of success. Fortunately, there
have been a number of signifi cant developments recently in the
pelletizing machinery fi eld, including some highlighted at June’s
NPE trade show in Chicago.
There, for the fi rst time, Crown Machine uwp Inc. (Addison,
IL) revealed its newest development, a system that is truly a
one-button operation and requires no centrifugal dryer but offers
twice the efficiency of one of these, according to George Holmes,
founder and owner of the company. Speaking with MPW at NPE,
Holmes called his development “the only true auto-start pelletizer
available.” Magnets release to allow access to the die, with the
rear part of the unit returning to the rear as per the bolt on a rifl e,
so that die changeover is swift and even a change from black
Automatik recently installed four new strand pelletizing lines for a European
polyamide supplier.
to white pellets is possible in just a few minutes. The magnetic
clamp is patented and was shown for the fi rst time at NPE.
Also at NPE, Automatik Plastics Machinery GmbH (formerly
Rieter Automatik; Grossostheim, Germany) introduced its Baoli
strand pelletizer, designed specifi cally for the U.S. compounding
market. The manufacturer says the system is cost-effective
in terms of purchase price and running costs, and available
in three basic machine sizes with operating widths of 100-,
200-, and 300 mm.
In early July, Automatik announced the sale and installation
of four new strand pelletizing systems for use in a new
polyamide supply facility in Europe. The four horizontal lines
are based on the M-USG 600 H underwater strand pelletizer,
each with a throughput capacity of 3200 kg/hr. Each of the
systems includes a fl uid-headed die head to melt the feed
and extrude the strands, a horizontal strand guide section,
the pelletizer, and a Centro 300 centrifugal dryer to remove
process water from the cylindrical pellets.
The Converting Systems Group of Davis-Standard (Fulton,
NY) recently added new pelletizing technology to its Black
Clawson Converting Machinery range. Charles Crumb, business
group manager at the company, told MPW redesigned dies
with more holes per die were developed, increasing through-
mpw.plasticstoday.com
put, and the die
plates have been
strengthened to
increase service
life by 25-30%.
These dies are
retrofi ttable on
installed systems,
he said.
Innovation & Optimization Place
The company also added a new air ring pelletizer to its mix
of underwater and water ring equipment, with the new system
to help users process materials with low internal energy or
hydroscopic materials. Black Clawson’s pelletizers may be
unique in that the die is fi tted parallel to the ground.
Gala Industries Inc. (Eagle Rock, VA) has introduced
The Edge, an underwater pelletizing unit it says is able to
compete on cost with strand pelletizers, while offering the
benefi ts of an underwater system, such as no strand breakage
on highly fi lled concentrates. The Edge is compact and
suitable for throughput to 1000 kg/hr. Low maintenance
requirements and minimum operator attendance are two
of key advantages, claims Gala, along with low noise levels
and swift start-up times.
Gala also introduced its Electronically Adjusted Pelletizer
(Model EAC), with electronic motion control used to control
blade adjustment down to 0.0001 inch (patent pending),
according to Steven King, process equipment sales at the
100% employee-owned company.
In related news, Scheer Bay early this summer ended its
joint venture with CF Scheer after more than 10 years. Insolvency
proceedings for CF Scheer were opened in Germany
on Oct. 1, 2008 and its operating assets were sold. “Scheer
Bay Co. has always been independent
of CF Scheer and
was not part of the sale,”
said Tom Kernstock,
executive VP, who
added that the company
will continue
to operate under its
original name, Bay
Plastics Machinery
Co., from its facility
in Bay City, MI,
and will continue
to support its exist-
ing customers with
parts and service
for their equipment.
Matt Defosse
Crown’s George Holmes (right) and Amy Nepywoda,
design engineer, at the company’s NPE stand with
its newest pelletizing unit.
More holes per die plate, and strengthened
plates, lead to more throughput and longer service
life, says Davis-Standard’s Black Clawson
business unit.
MODERN PLASTICS WORLDWIDE • JULY/AUGUST 2009 25

PROCESSING TECHNOLOGY
PRODUCT WATCH
INJECTION MOLDING
Cinpres adds a rep, offers
Moldfl ow services
Gas injection technology (GIT) equipment provider Cinpres
Gas Injection has added to its growing network of service
and sales agents by appointing Simap as a representative for
Jon Butler, Cinpres’ managing director.
Slovakia, the Czech Republic, and Hungary. Last year Cinpres
added a new agent in India, expanded its presence in China,
and appointed a new agent in Brazil.
In other news, the company says it now is licensed to use
Moldflow technology to analyze and advise its customers in
developing prototypes. This license only covers the molds that
Cinpres has been appointed to help develop and isn’t then
available for the molder to use independently of Cinpres; for
that, processors must acquire their own license from Moldflow.
Moldflow (Framingham, MA), acquired last year by
Autodesk, is the global leader in 3D digital prototyping and
analysis tools for the plastics industry.
Commented Cinpres Managing Director Jon Butler, “We’re
keen to help customers seize work currently being undertaken
using older processes...Some companies use the same materials
and the same processes, without question, for years. We’re
challenging the ‘we’ve-always-done-it-like-that’ mentality.”
Cinpres, Cheshire,England;
+44 1606-839800; www.cinpres.com
New Moldex 3D simulation
software available
Plastics design and analysis software supplier CoreTech System
is marketing its newest product, Moldex3D R9.1, which the
firm claims will prove the fastest true 3D analysis tool available
to injection molders. This update of the company’s established
Moldex software provides a number of new functions and
enhancements, such as enhanced parallel computing technology
and a new meshing kernel. It also is said to offer users more
accurate analysis results on multicomponent molding than on
previously released software.
Place
According to the developer, key features in Moldex3D
R9.1 include the enhanced performance of parallel computing
that could help users see acceleration gains of anywhere
from 3-10 times. The benchmark of Moldex3D R9.1 on a
4-node Core i7 PC-cluster shows more than 10 times the
performance improvement of 3D flow analysis on a case of
one million elements. Accuracy also is improved. Some 485
plastic materials were updated and added to the database. It
is said to completely support two-color (2K) molding/overmolding.
The supplier also says that new Gate and Runner
design wizards can help reduce the runner and gate design
process dramatically.
Pricing and more detailed product information are available
through the firm’s agents, with contact information available
at its website.
CoreTech System, Chupei City, Taiwan;
+886 3-560-0199; www.moldex3d.com
SVGC added to hot runner controls
A sequential valve gate controller (SVGC) has been integrated
into the hot runner temperature control systems supplied by
Gammaflux Europe, the Wiesbaden, Germany-based subsidiary
of this company.
Designed
for use with hot
runner systems
with needle-valve
nozzles, the SVGC
opens and closes
each nozzle individually
and independently
of all
the others. This
permits sequential
filling of the cavity
so that flow
lines either are
prevented from
forming or are
shifted to those
areas of the molding
that are not
mechanically and/
or optically critical.
The reduced
flow length per-
Shown here in the form of screen displays are (top)
the program for a hot runner system with 8 needle
valve nozzles (red: closed, green: open) and (bottom)
the operating status of the nozzles 9.61
seconds after commencement of the cycle.
mits a reduction in wall or section thickness, leading to weight
savings. Since the holding pressure is uniform throughout the
entire molded part, the reproducibility of the parts is said to
be improved. The integrated sequential valve gate controller is
available for use with 8, 16, or 32 pneumatically or hydraulically
actuated needle-valve nozzles.
Gammafl ux, Sterling, VA, U.S.A.;
+1 703-471-5050; info@gammafl ux.com; www.gammafl ux.com
26 JULY/AUGUST 2009 • MODERN PLASTICS WORLDWIDE mpw.plasticstoday.com

PROCESSING TECHNOLOGY
Innovation & Optimization
METAL INJECTION MOLDING
New magnesium sheet
technology
Building off magnesium’s weight advantage
over other metals, including aluminum,
a new technology reportedly
creates fine-grained strengthening of
magnesium alloys at low cost. Called
NanoMag and launched by magnesium
molding technology firm, Thixomat Inc.
(Ann Arbor, MI), the development is
described as a patented, environmentally
friendly process for the production of
high-strength, lightweight magnesium
sheet with nanometer microstructures
for automotive, aerospace, military, biomedical,
and other applications.
Ralph Vining, director of engineering
at Thixomat, told MPW a thixomolded
plate is the “core” of the NanoMag
process, which entails running that
molded plate through a series of steps
to “mechanically work the material.”
It is then heat treated to further optimize
mechanical properties. Vining said
Thixomat is in the process of developing
a properties database for the products,
which should be available by the end of
the second quarter.
“The current status of our business is
in the development stages,” Vining said,
“however, we have identified several key
areas where the material can add value
to an existing product. We will be scaling
up the operation during the next few
months to produce a larger sheet size
that will ultimately open up our potential
market.”
The technology, which was developed
in conjunction with the University
of Michigan’s Department of Material
Science & Engineering under a National
Science Foundation sponsorship, formally
launched at the Society of Automotive
Engineers’ SAE 2009.
NanoMag is based on Thixomat’s
Thixomolding Thermal Mechanical Process
(TTMP). The company says the
net result is a stronger, more formable,
and lighter-weight magnesium sheet with
a strength-to-density ratio comparable
to steel but at one-fourth the weight.
Because of its lighter weight, magnesium
mpw.plasticstoday.com
sheet can reduce vehicle weight and
thereby cut fuel consumption.
Thixomat Inc., Ann Arbor, MI, U.S.A.;
+1 734-995-5550; www.thixomat.com
BLOWMOLDING
Jomar marks 40th
anniversary with new
PET IBM line
The year 2009 marks injection blowmolding
machinery (IBM) supplier
Jomar Corp.’s 40th year in business, and
the company is marking the occasion
with a new IBM machine targeting polyethylene
terephthalate (PET) containers
up to 60 ml.
Bill Petrino, Jomar president, told
MPW the fully hydraulic PET 20 features
a quick-change mold system, utilizing
individual mold cavities that are
mounted on die sets, which he says can
be installed in a matter of minutes.
The number of cavities the PET 20
can run is determined by the container
size, with Jomar positioning the system
for runs in the 12-million-containers/yr
range. Jomar also reports that its vertical
plasticizer and accumulator system help
reduce energy consumption. Petrino said
that Jomar, which started business in
1969, has manufactured and sold over
1600 IBM machines in its 40 years of
business.
Jomar Corp., Pleasantville, NJ, U.S.A.;
+1 609-646-8000; www.jomarcorp.com
ROBOTS & AUTOMATION
Guaranteed for life
End-of Arm Tooling (EOAT) components
manufacturer SAS Automation
says it now will offer a lifetime guarantee
for its GRF-20 spring return-gripper
fingers that were purchased after January
1, 2009.
The warranty must be used by the
original purchaser, and the products
must be used in the manner intended
and not abused. The warranty has some
other minor clauses, and is limited to a
million cycles.
SAS Automation LLC, Xenia, OH, U.S.A.;
+1 937-372-5255; www.sas-automation.com
Place
Plastics
Processors
Polyolefins
Industry Workshop
CHEMICAL MARKET ASSOCIATES, INC.
CLICK mpw.plasticstoday.com/infolink
MODERN PLASTICS WORLDWIDE • JULY/AUGUST 2009 27

PROCESSING TECHNOLOGY
PRODUCT WATCH
AUXILIARY EQUIPMENT
Accurate dispensing is in the name
New from Process Control Corp. is AccuDispense, a single-dose, gravimetric
dispensing system for automated material weighing and loading. It delivers a
pre-selected weight of free-flowing material (powder, flake, granulate, or pellets)
directly to the process. AccuDispense is used when it is necessary to obtain preweighed
doses of material that do not need to be blended, but require an accurate
dispense. The AccuDispense design is based on the company’s Guardian Batch
Blenders, where it shares the same mechanics, controls, and software.
The supply hopper and feed gate are mounted above the weigh hopper. When
the dispense sequence is initiated by a manual start button or automated signal,
a programmable controller activates the pneumatic gate feeder to begin loading
material into the weigh hopper at a maximum feed rate. The single-point load cell
transmits weight-gain information to the controller, which steps down the feed
rate prior to reaching the target weight, for greater accuracy. The gate feeds the
weigh hopper with material until the desired material amount is achieved. Once the
desired weight is dispensed, the slide gate opens and dumps the measured ingredient
into a container, mixer, or a downstream process.
Process Control Corp., Atlanta, GA, U.S.A.;
+1 770-449-8810; www.process-control.com
TESTING EQUIPMENT
Vehicle components’ quality assured with special
analyzer
Injection molder of plastics automotive
components Karl Küfner
(Albstadt-Tailfingen, Germany) has
incorporated Mettler Toledo’s HR83
halogen moisture analyzer into its
manufacturing process for analysis
and control of moisture content in
plastics granules and components.
Hans Lang, head of quality management
at the processor says, “moisture
in plastics is a very important factor
influencing product quality, so we
routinely monitor moisture content
both before and during production
to ensure quality and consistency
standards across our range of products.”
He says they decided on the
HR83 device because it is easy and
quick to use and is suitable in production
environments. It provides
reproducible results. The processor
performs up to five tests/24 hr and
due to the results it has optimized
the company’s washing and injection
processes, he says.
Processor Karl Kufner sees the Mettler Toledo’s HR83
halogen moisture analyzer as an essential part of
production.
Mettler Toledo AG, Greifensee, Switzerland; +41 44-944-2211; www.mt.com
Innovation & Optimization Place
SOFTWARE
Online forum gives
users a voice in
software’s direction
IQMS is asking the experts, its users,
how its EnterpriseIQ ERP software can
be improved, launching a Community
Server that acts as an online user
group where IQMS licensees can submit
changes to the program that are voted
on by other users. If the modifications
are accepted they are then implemented
by the company. Randall Flamm, IQMS
president, told MPW that in the past,
the company has offered multiday user
groups where IQMS customers would
travel and, in a conference setting, submit
potential changes for the system. Flamm
says the new “agile software” approach
allows for an “ongoing user group that
can be active all year long” for changes
that occur at “the speed of light, instead
of the speed of an airplane.”
If a current customer doesn’t want to
accept the change that has been pushed
forward by the group, they can opt out
of it, and Flamm said that before any
modifications are implemented, IQMS
verifies they will not have a deleterious
effect on upstream or downstream
systems. Glenn Nowak, VP of IQMS,
said the Community Server, which has
undergone a soft launch before being
pushed out to its 500-plus customers, has
already generated interest from existing
clients. “[Community Server] is solving
the everyday business issues of our customers,”
Nowak said, adding the community
of users has put forward tweaks
to the program that IQMS had not anticipated
but are of value.
Flamm said business continues to grow
in the downturn, if at a slower rate, with
around 25 software implementations currently
underway. In 2007, anticipating a
downturn but not its depth, Flamm paid
off all the company’s debt, including
purchasing its buildings. In December
of that year, the company beefed up its
professional services group, hiring four
to boost that team to 16 individuals.
IQMS, Paso Robles, CA, U.S.A.;
+1 805-227-1122; www.iqms.com
28 JULY/AUGUST 2009 • MODERN PLASTICS WORLDWIDE mpw.plasticstoday.com

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For information about exhibiting, visit PLASTECshow.com or call 310/445-4200

DESIGN|FOCUS
Designing for disposables
Meeting the medical disposables
challenge
By Clare Goldsberry
Home care is becoming more predominant
as hospital stays become
shorter—even for some of the most
serious surgeries—as insurers have
reduced allowances for stays and payments
to hospitals. With healthcare
costs again in the spotlight, cost cutting
is pervasive, to include in the disposable
medical products arena.
Hitting goals for low production costs
often requires a new way of looking at these
single-use devices (SUDs) and designing
for manufacturability and reduced material
usage on the processing side, while considering
ease-of-use and minimizing the potential
for error on the patient side. Many of
the same considerations that are critical in
designing multiple-use medical devices are
also major considerations for SUDs.
Tom O’Brien, product marketing manager
for Lexan and Cycoloy and healthcare
industry manager for the Performance
Products unit at supplier Sabic Innovative
Plastics (Pittsfield, MA), says that one of
the trends in healthcare is increasing the
throughput of patients in the system.
“The longer you’re in an operating
room, the longer you’re being
treated, the more it costs,
and insurance companies
are paying less,”
says O’Brien. “In the
area of disposables,
we’re seeing certain
surgical
instruments that
have historically
been
fabricated
of metal
going to
There are many things to take into consideration when designing medical
disposable devices—particularly if they are for use outside the hospital or care
provider’s office—such as ease of use, safety, and cost.
plastic so they can
be disposable. It
eliminates the sterilization
process, and
allows the surgeon
to move right on
to the next surgery
with no delays.”
In one case,
O’Brien explains,
Sabic worked with
an OEM on a metal
skin stapler. “This
skin stapler had
between 20 and 25 components, so after
each surgery the entire device had to be
completely disassembled, sterilized, and put
it back together,” he says. “There was a
tendency to lose parts, and there was the
time it takes in the sterilizer. Today, they use
a disposable skin stapler.”
Dave Devito, product marketing manager
for Sabic’s LNP compounds product
line and healthcare
industry manager
for specialty products,
says that the
term “disposable”
spans a wide range of
products. “Disposable
might be an $800 skin stapler
or a $20 syringe. I
do know
the medical
device
companies are
Sabic Innovative Plastics’ Ultem
material was chosen when the OEM
switched from metal to plastics for
this skin stapler.
Transparency lends devices an aura of sterility; these
plastics generally allow for multiple sterilization methods.
investing in new products all the time,
but always watching their costs,” Devito
says. “Major device manufacturers are definitely
expanding more into disposables,
with combined functionality designed into
the product. They are coming out with new
products—doing some innovation. Minimally
invasive surgical devices are expanding
for more in-and-out procedures.”
Kevin Dunay, market segment leader,
medical polycarbonates NAFTA for Bayer
MaterialScience LLC (Pittsburgh, PA),
sees device companies asking for materials
allowing for longer flow lengths in multicavity
molds. Reducing costs to manufacture
also means designing for thinner wall
sections as well. “We see a growing trend in
the health care market for thin-wall applications,”
Dunay says.
To address the demand for these, his
company in June launched its Makrolon
Rx2435 polycarbonate. Like its predecessor,
Makrolon Rx2530, Makrolon Rx2435
resin exhibits a good balance of mechanical
strength and toughness, but the new
grade also adds easier flow, specifically to
meet the needs of thin-wall applications.
30 JULY/AUGUST 2009 • MODERN PLASTICS WORLDWIDE mpw.plasticstoday.com

Bayer MaterialScience’s
new Makrolon Rx2435
is used in
catheter connectors.
Potential thin-wall applications for Makrolon
Rx2435 include dialysis components,
catheter connectors, surgical instruments
—such as tracers, retractors and handles—
and drug delivery devices, he adds.
Dunay notes that SUD makers continue
to look at both new devices and “next-gen”
products. “Certainly it’s easier for the OEMs
to make small changes to a device they have
a history with,” he states. “They are continuing
to look at new technology, but they want
to be cautious, too, because they need a high
degree of safety and reliability.”
Sabic’s O’Brien explains that the OEM
typically works with the end user as they’re
designing new products. “The surgeons want
the feel—especially when an instrument goes
from metal to plastic—that it’s sturdy and
that it feels right in their hands. They need
the instrument or device to work the same
way each time.”
O’Brien says that in light of the economy,
new designs get put on hold more than they
used to. Also, approval time for new designs
can take a long time. “It might be more cost-
mpw.plasticstoday.com
effective to tweak a design on something
that’s already proven as it’s easier for them
to launch a redesign than come out with a
whole new product,” he says.
Single versus multiple use
If medical device OEMs move increasingly
toward SUDs—even in surgical
instruments—has the need for sterilization
waned? Sabic’s Devito says it’s not necessarily
the case. “It’s still critical in application
development to look at sterilization requirements,
and it’s one of the main questions
asked in the development process,” he says.
“I think it’s all about efficiency. And it’s still
one of the main CTQ (critical to quality)
issues when device makers promote their
products in healthcare.”
Bayer’s Rx2435 grade also addresses the
increasing demand for a radiation-stabilized
ISO certifi cation opens medical doors
Mack Prototype Inc. (Gardner, MA), a division of custom injection molder Mack
Molding Co. and specializing in SLA rapid prototyping, CNC machining, and injection
molding (8 presses sized 10-230 tons) for low-volume, small-to-medium parts
processing, recently received its ISO 13485 certifi cation, the international quality
standard for medical device manufacturing. “Achieving this quality hallmark uniquely
positions us as a prototype house and low-volume manufacturer, as many manufacturers
our size are not certifi ed to this stringent medical standard,” says Rick Perry,
president of Mack Prototype. “It will put us at the table with major medical OEMs,
who require suppliers to be certifi ed to ISO 13485 in order to quote new projects.
And based on customer needs, it will allow us to partner with Mack Molding, which
is FDA registered and has been certifi ed to ISO 13485 for several years, to provide
a low-volume solution for major medical OEMs.”
Michael Hanson, senior technical development engineer at the processor,
explains that when designing medical disposables, it’s important to start with a target
cost, which narrows the scope of possibilities. “Another often overlooked step is to
clearly defi ne that part’s requirements,” Hanson says. “The overall goal is to meet the
part requirements at the lowest possible cost, so this is where you must start.” Other
design considerations he mentions include avoiding sharp edges that could easily
prick surgical gloves; avoiding thin and thick sections to minimize molded-in stress
levels and part warpage, and, of course, choosing the correct resin.
medical grade of polycarbonate. It is gammastabilized
and typically offered in the color
Gamma (color code 451118), but can also
be colored in any of the company’s other
Rx Medical colors, all of which meet the
requirements of FDA-Modified ISO 10993,
Part1 tests with human tissue contact time
of 30 days or less. Sabic’s portfolio includes
materials that can meet every type of sterilization
requirement including gamma and
steam autoclave, which are the primary
methods, notes O’Brien. “With gamma you
have color shift but our products have color
stabilizer in them so when PC devices are
gamma sterilized they don’t shift toward yellow
as much. It will shift a bit, then go back
to clear. A lot of disposables are gamma
sterilized because it’s quick.”
With steam autoclave sterilization, there
are two temperatures used, 134ºC or 121ºC.
“Hospitals prefer the 134ºC because it’s
quicker. You’re talking more robust materials
for that, so it’s a trade-off. A lot of disposables
like Y-sites, stopcocks, are PC that is
generally gamma sterilized at the OEM, used
once, and tossed. It all depends on the type of
sterilization method,” says O’Brien.
O’Brien is confident about the strength
of the SUD market, but with reservations.
“I think we’re seeing more applications
and new products, but we’ve also seen
that healthcare isn’t recession proof,” he
says. “We’ve seen budget cuts in hospitals,
OEMs moving a bit slower on new
products than they used to. It’s still a
good market, but they look at costs a lot
more closely than they used to and ask
that big question: What can I do to take
costs out? MPW
mpw.plasticstoday.com
Click on the “Design Focus” tab for tips
on specifying the right plastics in medical.
MODERN PLASTICS WORLDWIDE • JULY/AUGUST 2009 31

WORLD TOUR
By Robert Colvin
It wasn’t always that way. Back in 1982,
Phil Tredway, who had been working
in international banking in Montreal
for eight years, decided it was time to
start out on his own. So he and his wife
moved back to their hometown, Erie,
where he started his injection molding
operations using two presses financed
by Cincinnati Milacron (Batavia, OH)
in a rented warehouse with a staff of
three. Today he heads the company that
employs 50.
“At first we started processing overflow
work that Omni Plastics (also Erie)
couldn’t handle,” Tredway says. Other
work followed along with additional
custom molding of non-durable goods.
He says he often slept on a cot on the
shop floor to ensure that 24/7 operations
ran smoothly with so few people. The
company expanded during the 1980s
and located in a cluster of other plastics
NORTH AMERICA
Business, Strategies & Markets
Going lean means sustained business
Thomas Tredway says Erie has been
successful in designing and molding
specialty closures sold for snack food
containers.
Erie Molded Plastics (Erie, PA) is a shining example of how small-to-medium-
sized injection molders in developed regions can compete successfully by
specializing and through automation.
Father-and-son team (from left) Phil Tredway, president, and Thomas, sales manager,
are guiding Erie Molded Plastics toward more proprietary molding to be less
dependent on custom molding projects.
processors along Erie’s W. Ridge Road.
Everything seemed to be going fine until
2001, when customers starting pulling
work and outsourcing it overseas.
“We saw a need to expand our customer
base and to
do more proprietary
processing so as to
be less dependent
on custom molding,”
recalls Tredway.
That led to son
Thomas, who previously
worked during
high school and
university summer
vacation periods on
the shop floor, joining as sales manager; he
already had sales experience as a stockbroker
on the East Coast.
One of the recent proprietary successes
Erie Molded Plastics points to is a tamper-evident
cap it designed, molded, and
is now marketing. A U.S. snack food
Investing in
automation is a big
priority with us. It doesn’t
cost jobs, but allows our
existing workers to do
more meaningful work
here at the plant.
producer that previously sourced such
work from molders in Brazil decided
to bring the work back home and was
looking to work with a Pennsylvaniabased
molder. “For them, a local company
was easier to
talk to and logistics
were faster as
well,” says Thomas
Tredway. Today
the company has
revenues of up to
$7 million/yr, processing
3 million
lb/yr (about 1361
tonnes/yr) of resin,
two-thirds of which
are commodity materials while the rest
is mainly glass-filled nylon 6.6.
But father Phil indicates that the
operations still need to achieve a more
competitive edge and the company has
a number of projects in the works
designed to cut its overall costs and
32 JULY/AUGUST 2009 • MODERN PLASTICS WORLDWIDE mpw.plasticstoday.com

WORLD TOUR
improve product. “Investing in automation
is a big priority with us,” he says. “It
doesn’t cost jobs but allows our existing
workers to do more meaningful work here
at the plant.”
A strategic goal is to increase proprietary
processing up to 40% to be less
reliant on custom injection molding. The
launch of a successful line of caps and
closures, including a 48-cavity mold for
the body and closure of a European lip
balm product, point to success in this sector.
The company now has a 21-press park
sized from 85-750 tonnes clamping force,
all from Milacron, a move he says helps
reduce maintenance and downtime due to
machine uniformity.
The company is sourcing its tooling from
builders in Taiwan and China, although it
uses local moldmakers for maintenance and
repair. Another program is to reduce scrap
but Thomas admits, “We aren’t where we
want to be yet.” The plant has been airconditioned
to reduce sweating of molds.
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NORTH AMERICA
Business, Strategies & Markets
Erie Molded Plastics’ injection press park of Milacron machines includes one allelectric
unit.
To maintain its staff loyalty, the company
has initiated a profit-sharing program and
invests in continuing education.
Phil Tredway, who is a past-president
Call 866.879.9144 or
sales@fosterprinting.com
of the Society of Plastics Engineers, sees a
bright future for his and other local molders
who stress lean management and wellpaced
growth plans. MPW
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MODERN PLASTICS WORLDWIDE • JULY/AUGUST 2009 33

WORLD TOUR
ASIA-PACIFIC
Business, Strategies & Markets
Blue skies prevail in China; are
stormy skies ahead?
By Stephen Moore
They say you can gauge the health of
China’s export-driven economy by the
level of atmospheric pollution in Southern
China. Assuming that is true, then a recent
low smog-level drive through the industrial
city of Dongguan clearly indicated
that China’s export machine is suffering
as the global economy flounders. Indeed,
June’s exports from the country dropped
year-over-year by 21.4%, the eight straight
monthly decline, though the pace of decline
is slowing. The big question is whether
the domestic stimulus-driven recovery in
China is sustainable or not. Some opine
that the government succeeded in kickstarting
the domestic economy through
its stimulus efforts, but once the effects
of these have flooded through the system,
a repeat package of similar proportions
would be difficult, and China would thus
then depend on a global recovery to bolster
its export-led economy. Clariant’s Juer-
Most of the world may be mired in recession but China is exhibiting
resilience, according to industry insiders who spoke with us in late May at
the Chinaplas tradeshow in Guangzhou. The next months will tell if the
relatively good times can hold.
gen Heise, head of
Greater China in
Guangzhou, China
for the additives
and colorants supplier,
is one forecasting
such a twopronged
recovery,
saying, “We expect
the current run-up
to come to a halt
in a few months,
before a real recovery
around May
2010.”
However, Engel
Machinery Asia (Pyeongtaek, South Korea)
President Robert Bodingbauer expects the
current global crisis to boost China’s longterm
prospects. “Once the world recovers,
I think the majority of companies will
look at investing in production facilities in
Chinaplas 2009 attracted 69,298 visitors, including 11,340 from overseas.
Arburg’s Man: The strong get stronger.
Asia rather than
Europe and other
developed economies.
The main
beneficiary will
be China,” stated
Bodingbauer.
Southern China
export strife
The plastics processing
sector in
Southern China
presently is characterized
by two
extremes, according
to Max K.W. Man, general manager at
injection molding machine manufacturer
Arburg’s Shenzhen operation. “They either
have no work whatsoever or they are busy.
Customers are looking for the strongest
companies when they place their orders,”
he said. The rest of the year will likely be
critical to the survival of many, he predicted.
“Processors reliant on export orders
have to prove to the banks that they have
orders in order to get financing,” said Man,
who added that while Arburg has suffered
from the downturn, it has not been hit to
the same extent as machine suppliers serving
the low-end market. “We have already
seen some confidence restored in the second
quarter, although machine buyers are
taking longer to sign,” he said.
Healthy homeland
Domestically the picture remains relatively
bright. Since March, various
government stimuli and initiatives have
kicked in, and the local economy has
begun to tick again. While the major-
34 JULY/AUGUST 2009 • MODERN PLASTICS WORLDWIDE mpw.plasticstoday.com

WORLD TOUR
ity of China’s $586 billion fiscal stimulus
package is destined for infrastructure and
construction, other government initiatives
are boosting the processing sector. Tax
rebates have seen auto sales in China at
record levels of late, while ready availability
of credit and VAT (Value Added
Tax) rebates have boosted capital investment.
A voucher distribution program
has ignited appliance demand, to cite
another example.
As part of its efforts to boost the local
economy, China in January exempted
purchases of injection molding machines
from a 17% VAT burden, a move that
helped drive sales, according to Helmar
Franz, chief strategy officer of Ningbo
Haitian Co. (Ningbo, China). “After an
extended New Year break, buying activity
returned in March and we are now
at 80% of the peak level of 2008,” said
Franz, who has also noticed a fall-off
in production at many multinationals
in China. “In a recession, it’s easier to
mpw.plasticstoday.com
ASIA-PACIFIC
Business, Strategies & Markets
lay off people and cut back on production
in China than in a home market in
Europe.”
Echoing Haitian’s sentiments, Taiwan’s
Fu Chun Shin (Tainan) reported
that orders in January and February
of this year were at just 20% of the
level of 2008. However, “During March
through May, we returned to a level of
70%,” said John Hsieh, planning department
manager. “Outside China, Africa is
doing quite well because it’s not as integrated
into the global economy.”
Packaging progress needs more
efficient equipment
Netstal China Ltd. (Shanghai) is also
“quite happy” with recent business in
China. General Manager Andreas Nydegger
said his company is gaining market
share in the higher cavitation market for
72- and 92-cavity PET perform molding
systems, though this remains a smaller
market than that for lower cavitation units.
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“The key to success in the China market
is (supplying) machines that are easy to
set up and maintain. Chinese processors
are not quite ready for the cavitations of
144 and even 192 that we are seeing in
North America,” said Nydegger. He added
that Chinese processors are showing an
increased appreciation for the benefits of
reliability, less material usage, and faster
cycle times. Although a typical Netstal rigid
packaging system costs four times more
than 15 Chinese machines, production efficiency
is better by a factor of six to seven
and ROI is around one year, he claimed.
Packaging production efficiency will be
a key component of revisions that are to
be made to China’s packaging legislation.
Observers say this change will push industry
consolidation and demand for energy
efficient machinery.
Hosokawa Alpine (Augsburg, Germany)
Divisional Manager Christopher Tarrant
says orders for blown film extrusion
lines such as the ones his company makes
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MODERN PLASTICS WORLDWIDE • JULY/AUGUST 2009 35

WORLD TOUR
were put on hold in China for around
six months but now seem to be gaining
momentum. “It will take some time to
see if this continues but a lot of projects
that were shelved last year are restarting,”
stated Tarrant. In particular, petrochemical
joint ventures need flexible
plastic packaging for their production,
he said. Increased fertilizer production
in China coupled with a tendency to
switch from woven sacks to PE sacks is
also boosting demand.
Chinese processors naturally are also
looking to reduce their plastics’ cost by
reducing material use, which should drive
a shift to greater use of linear low density
polyethylene (LLDPE) for flexible packaging.
One thing standing in the way of
downgauging, however, is that Chinese
businesses continue to manhandle bags
rather than use automated handling.
“They are handled roughly and 120 μm
or 140 μm bags wouldn’t be able to handle
such treatment,” noted Tarrant. Cur-
ASIA-PACIFIC
Business, Strategies & Markets
Clariant’s Heise: W-shaped recovery.
rently the standard in the country is 160
μm. “China needs to revisit its logistics
system before downgauging to gauges of
advanced countries,” adds Tarrant.
Brückner (Siegsdorf, Germany),
meanwhile, has received orders for seven
bi-oriented polypropylene (BOPP) and
polyethylene terephthalate (BOPET)
lines in China so far this year, and officials
there reason it is benefiting from the
availability of financing and a relatively
strong local economy. “At present, processor
margins are slim but their operating
rates are high so cash flow is good,”
noted Phillip Chen, managing director
of Brückner Far East (Hong Kong). As
Chinese processors invest in the more
cost-effective lines, older lines will have
to be shut down or be devoted to niche
products, according to Chen.
“We expect to sign a few deals after
the Chinaplas show,” said Peter Oswald,
managing director of tenter equipment
manufacturer DMT Guangzhou Machinery.
The two latest BOPP projects in
Asia for the manufacturer are at processors
Paoyan (Taipei) and Zhejiang Yiwu
YiMei Film Industry (Yiwu, Zhejiang
Province). Both lines are equipped with
DMT’s TDO inlet sprocket drive, which
CLICK mpw.plasticstoday.com/infolink
36 JULY/AUGUST 2009 • MODERN PLASTICS WORLDWIDE mpw.plasticstoday.com

WORLD TOUR
reduces the chain load and results in
higher uptime with lower energy and oil
consumption.
YiMei just installed its second 450 m/
min line from DMT. “Higher output is
the key requirement in the industry on
account of its commodity nature, but
there is some interest in specialty lines,”
said Oswald. Zhejiang Hangbao Group
Co., for example, operates a 5-layer high
barrier line from Oswald’s firm. There’s
also a need for flexibility to switch from
commodity to specialty products using the
same line. For example, Fujian Quanzhou
Lichang Plastic Co., switched from BOPP
film extrusion to production of synthetic
PP paper (filled with CaCO 3 ) when the
market had a previous downturn.
Jürgen Rehkopf, GM for the Asian-
Pacific headquarters in Singapore of
extruder manufacturer Reifenhaüser
(Troisdorf, Germany) was surprised how
busy Chinaplas turned out to be, saying,
“We had solid talks on technol-
P E P P 20 0 9
GLOBAL CONFERENCES,
STUDIES, PROJECTS
mpw.plasticstoday.com
ogy and will see
what comes out of
them…The ones
that didn’t survive
the crisis are not
our customers.
Now the larger
players are benefiting
from less competition.”Rehkopf
maintained that
in times of crisis,
processors with
the most efficient
machinery can
gain an advan-
ASIA-PACIFIC
Business, Strategies & Markets
tage. “We’ve had five contracts signed in
Southeast Asia and China this year. There
is demand for machines but definitely
a hurdle in terms of getting financing
because most money is going into large
projects,” he said.
Reifenhaüser’s Rehkopf also noted a
lot of international visitors from coun-
Haitian’s Franz: New low-cost Tianjian machine for local
market.
PEPP 2009
18th Annual World Congress
Polyethylene & Polypropylene Chain World Congress
Zürich, Switzerland, October 13–14–15, 2009
tries such as Morocco, Thailand, Mexico,
Chile and Pakistan.
“They want to see how close the
Chinese machine builders are getting to
us in terms of performance, and at what
price,” said Rehkopf. “We’re still ahead
but we need to keep an eye on the Chinese
competition.” MPW
Tuesday, October 13th Wednesday, October 14th Thursday, October 15th
Polyolefins Global Review I High Pressure PE /EVA
MBS (CH): Global PO Report
Access Intelligence (USA): C2 Report
Ineos (GB): HAOs Report
Sinopec BRICI (PRC): PO Technology
Tasnee (KSA): New Global PO Player
MATT Management (NL): HP PE Technology
LyondellBasell (DE): Lupotech*A Process
United Initiators (DE): LDPE Peroxides
SRI Consulting (CH): LDPE/EVA Markets
Polyolefins Global Review II PE/PP Process Technology
Oriental PC (EG): PO Challenges
Nova Chemicals (USA): Processes/Catalysis
Ineos (BE): HDPE Products
Borealis (AT): PP Pkg. Solutions
Vogt Plastic (DE): PO Recyclates
Chevron Phillips (USA): Process Technology
Ineos (FR): Dual PE Technology
Lummus Novolen (DE): Novolen* Technology
Univation (USA): Unipol* PE Process
Polyolefins Logistics Polyolefin Catalyst Update
Zeppelin (DE): PO Logistics Chain
Haver & Boecker (DE): Packaging/Distrib.
Interbulk (NL): Suppy Chain Mgmt.
K. Schmidt/Agility (DE): Logistic Trends
Akzo Nobel (NL): Aluminoxane Grades
Albemarle (USA): Polyolefin Catalysts
Lummus Novolen (DE): Catalysts Solutions
PQ Corporation (GB): Silica Catalyst
PE/PP Engineering Technology PE / PP Additivation / Modifications
Tecnimont (IT): Servicing PO Ind.
Coperion (DE): PP/PE High Cap. Lines
K-Tron (CH): Mixing/Dosing
Evening Hospitality Function
GLOBAL CONFERENCES,
STUDIES, PROJECTS
The sources for chemical and plastics insight and intelligence
Songwon (CH): TNPP Replacement
Chemtura (BE): Additives for Efficiency
Milliken (BE): Speciality Additives
Omya (CH): Mineral Modifiers
MAACK BUSINESS SERVICES
Maack & Scheidl Partnership PLASTICS TECHNOLOGY AND MARKETING
CH-8804 Au/near Zürich, Switzerland Tel: +41-44-781 30 40 Fax: +41-44-781 15 69
E-mail: MBSpolymer@bluewin.ch www.MBSpolymer.com
OPEN HOUSE EVENT
Thursday morning
by:
Omya International AG
(Oftringen, Switzerland)
Invited Panelists
(Global Review Sessions)
Converters:
Manuli Stretch
Schöller Arca
Tetra Pak International
Brand Owners:
Johnson & Johnson
Procter & Gamble
Unilever
CLICK mpw.plasticstoday.com/infolink
MODERN PLASTICS WORLDWIDE • JULY/AUGUST 2009 37

WORLD TOUR
EUROPE
Business, Strategies & Markets
Innovation key to future for Serbian
processors
By Robert Colvin
Barrier-film processor Spektar (Gornji
Milanovac), after installing a 7-layer,
biaxially oriented, blown shrink-wrap line
from Kuhne Anlagebau (Sankt Augustin,
Germany) five years ago (April 2004
MPW, p. 45), has embarked on a project
offering even higher barrier. The
processor was named 2007 Exporter of
the Year by the government for its innovative
packaging products, which are
sent to markets throughout Europe, the
surrounding Balkan states of the former
Yugoslavia, Russia/CIS countries, and
even North America, where the processor
is eager to find a distributor.
Spektar owner Zoran Dordevic,
together with his two sons, has opted
for a 9-layer, triple bubble system, producing
web in 25-100-μm tolerances, on
a line delivered from Kuhne but with its
design based on Spektar’s 5- and 7-layer
production experience, he says. The new
unit allows up to 50%
better shrink properties
for packaging of meats
and cheese.
Son Petar Dordevic
says the unit will complement
the company’s
offering since 7-layer
film (40-100 μm) produced
there provides
better puncture resistance
for packaging
such things as fresh
meat with sharp bones.
“We want to be able
to offer customers the
optimum choice of film
structures to match
their products,” he
says.
Petar Dordevic adds
The first 10,000 injection
molded instantaneous hot
water heaters left Serbian
processor RPC Pesovic for
delivery to a South African
building developer in April.
Although Serbia is a small European country, big things are happening there in
plastics processing as discovered on a recent return visit by Modern Plastics.
that the 9-layer line
also yields substantial
future possibilities.
For example,
for cheese packaging
that Spektar started
targeting last year,
he foresees a 9-layer
film with a selective
barrier, permitting
CO 2 that cheeses
produce to be evacuated
while preventing
oxygen ingress.
Better-controlled
barrier for poultry
packaging is also
possible.
During the last
two years the company invested about
€5 million not only in the 9-layer line
but also in a new building addition to
house the unit and an
8+8 color flexographic
printer from Windmöller
& Hölscher (Lengerich,
Germany), delivered in
June of this year. The
expansion also required
the company to meet
new fire regulations and
since the local community
could not guarantee
enough water delivery in
case of fire, Spektar was
required to install water
storage on the premises
Award-winning designer and injection molder P. Peshovich,
owner of RPC Pesovic, demonstrates his injection molded,
tankless, energy-saving water heater, recently delivered to
a South African customer.
in case of a blaze. Zoran
Dordevic decided if he
had to include that, then
the storage should be in
the form of a swimming
pool, which staff and
families use after work.
At blown-film processor Bel Plast
(Bela Zemlja), Manager Sanja Spijunovic
saw enough growth potential to install a
new 3-layer line from Kuhne primarily
dedicated to linear low-density polyethylene-based
stretch-hood production
for pallet wrap targeted at such products
as cement bags, cinder blocks, and
roofing tiles. The €2 million line with
inline printing is also versatile enough,
says Spijunovic, that it can be used to
produce biodegradable shopping bags
for Serbia’s largest supermarket chain,
Delta. Film line troubleshooting is handled
by remote diagnostics.
At processor and toolmaker RPC
Pesovic (Simanovci), a new complement
to the existing injection molded water-
and energy-saving sanitary fixtures line
is a plastic instantaneous water heater.
Originally RPC Pesovic was only to supply
the fixtures but its co-vendor for hot
water boilers was incapable of supplying
38 JULY/AUGUST 2009 • MODERN PLASTICS WORLDWIDE mpw.plasticstoday.com

WORLD TOUR
the necessary number of units for the
project in the designated time.
“We were asked to take over the
complete development of the system, but
we had no experience in producing water
heaters,” says Vojin Peshovich, marketing
director and son of the owner. “We
“
Generally a
[traditional] water heater
wastes up to 1000 kWh of
energy just keeping warm
water available. Our unit
eliminates that.
”
came up with a solution in 30 days and
another 90 days was necessary to build
the required molds and stamping tools.”
The result is a mini (500g) injection
molded tankless water heater that is said
to waste no energy.
mpw.plasticstoday.com
EUROPE
Business, Strategies & Markets
Unlike insulated heaters
that heat up water and hold
it warm for use, this unit provides
instant warm water on
demand. “Generally a [traditional]
water heater wastes
up to 1000 kWh of energy
just keeping warm water
available. Our unit eliminates
that—as well as the
wait until the warm water
reaches the faucet through
the pipes (an average of
3.5L loss), since this unit is
installed directly above the
faucet for a shower, tub, or
wash basin,” he says.
Development of this injection
molded project, using a blend of engineering
resins to cope with the 70-80°C
water temperatures, started last November,
and delivery of the first 10,000 units
to the South African building and construction
customer took place in April.
CLICK mpw.plasticstoday.com/infolink
Climbing up the barrier-film processor’s new
9-layer web tower to inspect operations are (from
left) Spektar Managing Director Zoran Dordevic
and son Petar.
“Fast reaction was needed on this project
along with particular attention to endproduct
quality,” says Peshovich. The
company is now seeking certification
of this unit so that it can be marketed
throughout the European Union. MPW
MODERN PLASTICS WORLDWIDE • JULY/AUGUST 2009 39

2009 Auxiliaries & Supplies Directory
Contents
Companies are arranged alphabetically within the following categories:
Blenders/feeders/dosers ................................................................................. 40
Blown film extrusion ....................................................................................... 40
Compounding systems .................................................................................... 40
Decorating/printing equipment ....................................................................... 41
Dryers ............................................................................................................. 41
Extrusion systems, blown film ........................................................................ 41
Extrusion systems, pipe & profile .................................................................... 41
Extrusion systems, sheet ................................................................................ 42
Gear pumps .................................................................................................... 42
Hoses for material handling ............................................................................ 42
Measurement/testing equipment ..................................................................... 42
Microcellular gas dosing & supercritical fluid delivery systems ...................... 42
Molds, dies & components .............................................................................. 43
Pad printing machines .................................................................................... 43
Pelletizing systems ......................................................................................... 43
Recycling systems .......................................................................................... 43
Screen changers ............................................................................................. 43
Shut-off nozzles ............................................................................................. 44
Size reduction equipment ............................................................................... 44
Temperature controls ...................................................................................... 44
Thermal analysis, analyzing & testing ............................................................. 45
Welding/sealing/bonding equipment ............................................................... 45
Winding equipment ......................................................................................... 45
Requests for information on listing in future issues should be sent to Iris N. Topel,
Modern Plastics Worldwide, P.O. Box 690577, East Elmhurst, New York 11369
Tel: +1 718-478-8104 • Fax: +1 718-478-8105 • iris.topel@cancom.com
BLENDERS/FEEDERS/DOSERS
Plastrac Inc.
3928 Miller Rd., PO Box 1067
Edgemont, PA 19028 United States
610-356-3000; 610-356-7022 (fax)
sales@plastrac.com
www.plastrac.com
Plastrac Inc. manufactures Disc-based Blending
and Dosing equipment and hopper loaders for
all plastics processing. Blending and Dosing units
include gravimetric self-calibrating Dosing units,
multi-ingredient blenders and volumetric color
proportioning equipment. A modular design concept
makes Auto-Disc units capable of fast material
changes. Loaders include both individual units
and mini-central conveying systems. Models are
available as machine-mounted or floor-mounted
equipment. Micro-feeding units provide inherently
consistent feeding characteristics and are being
used in production to add less than 0.02% color
per shot with micro-pellets and micro-beads.
BLOWN FILM EXTRUSION
Addex Inc.
154 Maple St.
Stoughton, MA 02072 United States
781-344-5800; 781-344-5766 (fax)
addex@addexinc.com
www.addexinc.com
Supplier of Premier Blown Film Equipment. In the
age of high resin prices issues like controlling the
overall thickness variation, controlling the thickness
of expensive barrier layers, tight layflat control
and low scrap rates become very important!
The good news is Addex has excelled in these for
years. In 2009 Addex added GRAVEX a Continuous
Gravimetric Blending system to its offerings to
address all aspects of raw material savings.
COMPOUNDING SYSTEMS
Coperion GmbH
Theodorstr. 10
Stuttgart 70469 Germany
49-711-897-2301; 49-711-897-3999 (fax)
info@coperion.com
www.coperion.com
Coperion, formerly Werner & Pfleiderer, Waeschle,
Keya and Hartmann, is the worldwide market and
technology leader in compounding & extrusion,
materials handling and service. Across the world
we implement individual and turnkey solutions
for compounding technology and bulk materials
handling. This covers the full added value chain
of the production process from consultation and
planning, through engineering, process optimization,
manufacturing, delivery, installation and
commissioning to our worldwide service network.
Our service structure, consisting of 27 efficient
service centers and more than 250 service technicians
all over the world, enables us to act quickly
and directly wherever our customers need us.
Coperion-wherever material is compounded and
conveyed:
• polyolefins
• engineering plastics
• masterbatches
• long fiber-reinforced plastics
• PVC
• wire and cable compounds
• powder coatings/toner
• chemistry and reaction engineering
• minerals
• food
• pharma.
Get the best global plastics
news roundup.
Subscribe to MPW’s
e-Weekly.
Simply go to
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on our home page
to sign up.
40 JULY/AUGUST 2009 • MODERN PLASTICS WORLDWIDE mpw.plasticstoday.com

DECORATING/PRINTING EQUIPMENT
ITW Trans Tech
475 N. Gary Ave.
Carol Stream, IL 60188 United States
630-752-4000; 630-752-4460 (fax)
sales@itwtranstech.com
www.itwtranstech.com
Founded in 1979, ITW Trans Tech designs, fabricates
and supplies pad printing, laser, and digital
inkjet printing equipment to provide complete
product decorating solutions for a wide range of
industries. The Illinois Tool Works (ITW) company
offers a full line of standard equipment as
well as custom automated systems to manufacturers
of medical devices, automotive components,
sporting goods, appliances, hand tools, communications,
and plastic injection molders. ITW Trans
Tech provides a single source of consumables,
including: silicone pads, printing plates, standard
and specially formulated inks, and other printing
supplies and accessories. The company continuously
supports its products and customers with
the largest experienced team of service experts in
North America.
DRYERS
The Witte Company, Inc.
507 Route 31 South, PO Box 47
Washington, NJ 07882-0047 United States
908-689-6500; 908-537-6806 (fax)
info@witte.com
www.witte.com
Witte designs and manufactures the “Witte”
Screener as well as a combination Fluid Bed Dryer/Cooler/Screener
for the Plastics Industry. The
Witte Screeners are considered by most to be the
standard of the industry due to their separating efficiency,
ease of cleanability and low maintenance.
The Witte Cooler can typically remove 100°F in
three (3) feet of length. Test facilities are available
in Washington, NJ, which can demonstrate
our Cooling, Drying and Separation capabilities.
Please call to arrange a trial.
mpw.plasticstoday.com
EXTRUSION SYSTEMS,
BLOWN FILM
Alpha Marathon Film Extrusion
Technologies Inc.
170 Hanlan Rd.
Woodbridge, ON, L4L 3P6 Canada
905-265-2055; 905-265-8817 (fax)
alpha@alphamarathon.com
www.alphamarathon.com
Alpha Marathon Film Extrusion Technologies
Inc. (AMFETI) is an OEM of complete turnkey
systems and extrusion components to the blown,
cast, bubble forming and converting industry.
Alpha is a custom machinery manufacturer with
over 35 years of design, engineering and supplying
of innovative and patented technology improving
film quality and output worldwide in more than
20 countries. While the core of our business and
expertise is blown film dies AMFETI also special-
Internet Index
Extrusion systems, pipe & profile
izes in state-of-the-art winding technology and is
successful in combining these and other quality
assets into complete turnkey systems, quality assured.
EXTRUSION SYSTEMS,
PIPE & PROFILE
Versa Machinery
4850 Green Ct.
Elkhart, IN 46516 United States
574-266-0780; 866-44VERSA
574-266-0762 (fax)
Sales@VersaMachinery.com
www.versamachinery.com
Versa Machinery is a manufacturer of Cutters,
Pullers, Transport Conveyors, Air Ejectors, and
Addex Inc. www.addexinc.com
Agr International, Inc. www.agrintl.com
Alpha Marathon Film Extrusion Technologies Inc. www.alphamarathon.com
bielomatik inc. www.bielomatikinc.com
Coperion GmbH www.coperion.com
CROWN Machine uwp., Inc. www.crown-cdl.com
Dukane-Intelligent Assembly Solutions www.dukcorp.com/us
ElektroPhysik USA Inc. www.elektrophysikusa-plastics.com
EMC2 Inc. www.emcsquared.com
Gneuss, Inc. www.gneuss.com
Gneuss Kunststofftechnik GmbH www.gneuss.com
Herrmann Ultrasonics, Inc. www.herrmannultrasonics.com
Herzog AG, Degersheim www.herzog-ag.com
Hosokawa Alpine Aktiengesellschaft www.alpinehosokawa.com
ITW Trans Tech www.itwtranstech.com
Key Filters, Inc. www.keyfilters.com
Kuriyama of America, Inc. www.kuriyama.com
Maag Pump Systems AG www.maag.com
Netzsch Instruments Inc. www.e-thermal.com
NGR Next Generation Recyclingmaschinen GmbH www.ngr.at
Pad Print Machinery of Vermont Inc. www.padprintmachinery.com
PALLMANN Pulverizers Co., Inc. www.pallmannpulverizers.com
Parkinson Technologies Inc., Marshall and Williams Plastics www.parkinsontechnologies.com
Plastrac Inc. www.plastrac.com
Rotogran International Inc. www.rotogran.com
SINGLE Temperature Controls, Inc. www.single-temp.com
SML Maschinengesellschaft mbH www.sml.at
StackTeck Systems Ltd. www.stackteck.com
Trexel, Inc. www.trexel.com
Versa Machinery www.versamachinery.com
The Witte Company, Inc. www.witte.com
MODERN PLASTICS WORLDWIDE • JULY/AUGUST 2009 41

2009 Auxiliaries & Supplies Directory
Cut Length/Batch Controls for the plastic and
rubber extrusion industries. The company offers a
broad line of products that cover a wide spectrum
of extrusion applications. Versa Machinery has experience
processing a variety of materials. Specialized
products are offered that allow for accurate
measurement and cutting of elastic products like
silicone rubber and flexible PVC. At NPE 2009
(Chicago, IL, June 2009) Versa Machinery displayed
its De-Reeler/Dancer system that facilitates
the de-reeling of elastic and tacky materials in a
uniform manner, without stretching. Versa Machinery
also displayed a Servo Cutter/Servo Puller
combination system at NPE 2009.
EXTRUSION SYSTEMS, SHEET
SML Maschinengesellschaft mbH
Bundesstrasse 1a
Lenzing 4860 Austria
43-7672-912-0; 43-7672-912-9 (fax)
sml@sml.at
www.sml.at
100% extrusion lines for leading companies. SML
(Starlinger Maschinen Lenzing), with its head office
in Lenzing, Austria, is specialized in building
high-performance extrusion equipment based on
nearly 40 years of experience. SML has focused
on the development of coextrusion lines for film,
sheet and laminates as well as on extrusion spinning
lines for multifilaments. Besides supplying
custom-made extrusion lines SML offers holistic
and reliable concepts to support customers in the
realization of complex products. SML puts high
value on service and long-term business-relationships
and regards its customers as partners. Offices
for sales and service in Beijing, Kuala Lumpur,
Chicago and Moscow as well as more than 60
agents guarantee optimal customer proximity and
access to all important markets worldwide.
GEAR PUMPS
Maag Pump Systems AG
Aspstrasse 12
Oberglatt 8154 Switzerland
41-44-278-8200; 41-44-278-8201 (fax)
welcome@maag.com
www.maag.com
Maag Pump Systems develops and manufactures
gear pumps, filtration systems and screen changers
for the plastic and chemical industries and established
himself as the technology and market leader
in this particular business environment. Maag
Pump Systems success in the served markets lies in
devising solutions that balance considerations between
the technical and commercial aspects at every
stage of the process. As a market leader they have
a strong relationship to their customers. Whether
developing proprietary tools and programs or
working to stringent safety and quality specifications,
this passion for excellence creates top quality
products and is the reason why Maag Pump Systems
is the industry’s most trusted name.
HOSES FOR MATERIAL HANDLING
Kuriyama of America, Inc.
360 E. State Parkway
Schaumburg, IL 60173-5335 United States
847-755-0360; 847-885-0996 (fax)
sales@kuriyama.com
www.kuriyama.com
Kuriyama of America, Inc., is celebrating its 41st
year of providing quality hose products to the processing
industry. Tigerflex PVC/Polyurethane
and PVC suction and material handling hoses
allow visual monitoring of material flow. An embedded
copper grounding wire is used to dissipate
static electricity. Hose Tec® interlocked metal hoses
provide excellent abrasion resistance for use in
higher temperature applications and are available
with special swivel fittings. Kuri Tec® offers PVC
non-reinforced tubing, yarn and (non-kinking)
wire-reinforced hoses and the new Polywire® Plus
hose which offers both wire with yarn reinforcement
that can be used for powder and liquid transfer
applications.
MODERN PLASTICS WORLDWIDE
UPCOMING DIRECTORIES
PRIMARY PROCESSING
MACHINERY
DIRECTORY
December 2009
MEASUREMENT/
TESTING EQUIPMENT
Agr International, Inc.
615 Whitestown Rd.
Butler, PA 16001 United States
724-482-2163; 724-482-2767 (fax)
sales@agrintl.com
www.agrintl.com
Agr International, Inc., offers a variety of equipment
and services designed to meet the quality assurance
needs of the plastic container industry. Products
include in-line process monitoring systems for PET
containers, vision-based inspection systems for containers
and preforms, automated laboratory products,
and various manual gauges for use in the laboratory or
on the production floor. Agr International is committed
to being the industry leader in container testing
and process monitoring. Through continued research
and development at our Butler, PA, USA, headquarters,
our engineers are providing the technological
developments to meet the current and future quality
assurance needs of the plastic container industry.
ElektroPhysik USA Inc.
778 W. Algonquin Rd.
Arlington Heights, IL 60005 United States
847-437-6616; 800-782-1506
847-437-0053 (fax)
aivars@elektrophysik.com
www.elektrophysikusa-plastics.com
ElektroPhysik is a leading manufacturer of precision
non-destructive testing instruments for
coating thickness, material thickness, and other
surface and material properties. ElektroPhysik has
the CTM-S on-line thickness measurement system
for flat sheet goods. The CTM-S is designed
for measuring PET, PVC, PP, PS, HDPE, LDPE
and more. In addition, ElektroPhysik has the
FH-Series wall thickness gauges designed for nondestructive
wall thickness measurement of bottles
and containers. Also, the QuintSonic for coating
thickness testing over plastics is available from
ElektroPhysik. Contact ElektroPhysik at 847-
437-6616 for further information.
MICROCELLULAR GAS DOSING
& SUPERCRITICAL FLUID
DELIVERY SYSTEMS
Trexel, Inc.
45 Sixth Rd.
Woburn, MA 01801 United States
781-932-0202; 781-932-3324 (fax)
info@trexel.com
www.trexel.com
42 JULY/AUGUST 2009 • MODERN PLASTICS WORLDWIDE mpw.plasticstoday.com

Trexel, Inc., offers The MuCell® Microcellular Foam
injection molding and extrusion technology. This is
a complete process and equipment technology that
facilitates extremely high quality and greatly reduces
production costs. The MuCell Process involves the
controlled use of gas in its supercritical state to create
a foamed product. With MuCell Molding, the technology
is targeted at precision and engineered plastic
components with maximum wall thicknesses of less
than 3mm. The MuCell Extrusion Process offers
the greatest advantage to extrusion processors who
MUST HAVE the added performance of very small
closed cells or MUST HAVE an environmentally
clean solution. The small closed cells improve many
properties compared to standard foaming techniques
such as impact, ductility, insulation, sealability, and
appearance. Trexel also supplies high performance
Nitrogen and Carbon Dioxide Supercritical Fluid
Delivery Systems in all size ranges for other industrial
applications beyond microcellular foaming.
MOLDS, DIES & COMPONENTS
StackTeck Systems Ltd.
1 Paget Rd.
Brampton, ON, L6T 5S2 Canada
416-749-1698; 416-749-2795 (fax)
stackteck@stackteck.com
www.stackteck.com
StackTeck Systems Ltd. is a global provider of
sophisticated integrated plastic tooling solutions
for the injection molding industry. From product
and mold design to complete systems integration,
StackTeck develops injection molds and systems,
which provides the most effective and efficient
production solutions in the industry. Through
technical innovation in mold bases, quick product
change and multi-level stack molds, StackTeck
differentiates itself by delivering higher productivity
to the Caps, Closures, Thin Wall Packaging,
Technical and Medical markets. Dedicated testing,
service, repair and refurbishment resources
ensure the capacity to deliver global multi-mold
programs that are proven and deliver ongoing performance
year after year.
VISIT US AT
MPW.PLASTICSTODAY.COM
mpw.plasticstoday.com
PAD PRINTING MACHINES
Pad Print Machinery of Vermont Inc.
201 Tennis Way, PO Box 720
East Dorset, VT 05253 United States
802-362-0844; 800-272-7764
802-362-0858 (fax)
info@padprintmachinery.com
www.padprintmachinery.com
Pad Print Machinery of Vermont excels at “Engineered
Printing Solutions” in both the pad printing
and digital ink jet fields. Automation solutions include
bulk loading and unloading, optical & laser sensing
and positioning, conveying, robotic pick-and-place,
including integration of SCARA and 6 axis robotics,
custom software applications (including digital image
processing and remote diagnostics), plus a variety
of pre- and post-treatment options including corona
treating, flaming, UV curing and infrared conveyor
ovens. Whether your project is single-color or fullprocess
artwork, industrial equipment or consumer
goods, medical devices or automotive parts, Pad Print
Machinery of Vermont offers Engineered Printing
Solutions to improve the quality of your products
and your bottom line.
PELLETIZING SYSTEMS
CROWN Machine uwp, Inc.
5111 Vista Ave.
Addison, IL 60101-4422
630-543-5240; 630-543-4656 (fax)
sales@crown-cdl.com
www.crown-cdl.com
CROWN Machine (Addison, IL)—Designs and
develops innovative underwater pelletizers and
pellet dryers. These new Patented and Patent
pending designs will change the face of underwater
pelletizing. CROWN unveiled at ChinaPlas 2009
(Guangzhou, May 18-21) and exhibited at NPE
2009 (Chicago, June 22-26) the Super Belt Dryer,
a pellet dryer that de-waters, dries, fluidizes, and
classifies in one self-contained unit. The CROWN
pelletizing unit includes a servo-controlled underwater
pelletizer that provides precision control of
pressure of the cutting blades on the die face. In
addition to CROWN’s underwater pelletizing system
developments, CROWN shared at NPE 2009
how its Patent pending rotary dryer and tapered
screw densifier offer improved technology to recyclers
of polymer scrap.
Screen changers
RECYCLING SYSTEMS
NGR Next Generation
Recyclingmaschinen GmbH
Gewerbepark 22
Feldkirchen 4101 Austria
43-7233-70107-0; 43-7233-70107-2 (fax)
sales@ngr.at
www.ngr.at
NGR has changed the way of recycling plastic
waste. The idea is to replace the multi-step technology
with a cost-effective, compact and easyto-maintain
ONE-STEP technology. The revolutionary
NGR cutter-feeder-extruder combination
makes the entire recycling process more economical
by combining a powerful single-shaft cutter
with an extruder into one unit. That eliminates the
need for pre-cutting and densification of the material.
Such advantages mean a short period for your
return of investment. NGR is a manufacturer of
turnkey and custom-tailored plants for recycling
of thermoplastics with an output from 10 kg up
to 2.000 kg.
SCREEN CHANGERS
Gneuss, Inc.
10820-G Independence Pointe Pkwy.
Matthews, NC 28105 United States
704-841-7251; 704-841-7254 (fax)
gneuss.usa@gneuss.com
www.gneuss.com
Gneuss Kunststofftechnik GmbH
Mönichhusen 42
Bad Oeynhausen 32549 Germany
49-5731-53070; 49-5731-53077 (fax)
gneuss@gneuss.com
www.gneuss.com
Gneuss offers Filtration Technology, Measurement
Technology and Processing Technology.
Rotary Filtration Systems, highest quality continuous
and fully automatic screen changers, offer a
process constant mode of operation, with no pressure,
throughput or viscosity variations. Gneuss
Measurement Technology offers premium performance
melt pressure and temperature transducers/
transmitters, including the non-mercury NTX
MODERN PLASTICS WORLDWIDE • JULY/AUGUST 2009 43

2009 Auxiliaries & Supplies Directory
series. The innovative Multi Rotation System offers
new possibilities in devolatilization.
Key Filters, Inc.
100 Goldstein Dr., Highland Industrial Park
Woonsocket, RI 02895 United States
401-762-2100; 401-762-3313 (fax)
keysales@keyfilters.com
www.keyfilters.com
Key Filters is a manufacturer of screen changers
for plastic extrusion processes. We measure our
success based on the success of our customers. This
approach has made it possible for us to become a
leader in filtration machinery for the past 25 years.
Our product range consists of a complete line of
screen changers, which are able to meet the melt
filtration needs for any thermoplastic material.
• Continuous Screen Changers
• Hydraulic Slide Plate Screen Changers
• Manual Screen Changers
We offer a full range of guaranteed products, custom-engineered
solutions and turnkey service to
successfully meet your processing needs.
SHUT-OFF NOZZLES
Herzog AG, Degersheim
Huswiesstrasse 6
Wolfertswil 9116 Switzerland
41-71-394-1969; 41-71-394-1960 (fax)
info@herzog-ag.com
www.herzog-ag.com
Herzog has almost 40 years experience in engineering
and manufacturing machine shut-off nozzles
for the injection molding industry. Our shut-off
system functions with both needle and bolt technologies.
Additionally Herzog supplies pins for
the gas-assisted process. Herzog produces shut-off
nozzles for all kinds of plastics.
VISIT US AT
MPW.PLASTICSTODAY.COM
SIZE REDUCTION EQUIPMENT
Hosokawa Alpine Aktiengesellschaft
Peter-Doerfler-Str. 13-25
Augsburg 86199 Germany
49-821-5906-0; 49-821-5906-630 (fax)
plastics@alpine.hosokawa.com
www.alpinehosokawa.com
HOSOKAWA ALPINE-Recycling and Granulators
Division. For the in-house recycling of plastics,
Hosokawa Alpine has solutions for every
scale of application-from auxiliary granulators to
high-efficiency granulators with throughput rates
of up to 8 tonnes for the comminution of film.
Hosokawa Alpine designs, manufactures and supplies
complete granulator systems with all the requisite
system components, suitable for example,
for the comminution of thermoplastic scrap such
as sprues and runners, rejects, film webs or film
edge trims.
PALLMANN Pulverizers Co., Inc.
820 Bloomfield Ave.
Clifton, NJ 07012 United States
973-471-1450; 973-471-7152 (fax)
info@pallmannpulverizers.com
www.pallmannpulverizers.com
PALLMANN Pulverizers is a manufacturer of size
reduction equipment and systems including a line
of light and heavy-duty granulators available in
a range of sizes and specific rotor designs for different
applications. Profile shredders, rubber bale
knife mills, and heavy wall pipe granulators. We
also feature pulverizers in various sizes for batch
and lot laboratory use to large-scale production
runs. Systems can be provided with screening
units for closed-circuit operation or without for
one-pass output depending on customer requirements.
Rounding out the line are PALLMANN
Plast-Agglomerator densifying systems, which
produce free flowing granule from thermoplastic
materials.
Rotogran International Inc.
3 Bradwick Dr.
Concord, ON, L4K 2T4 Canada
905-738-0101; 905-738-5750 (fax)
mc@rotogran.com
info@rotogran.com
www.rotogran.com
Since 1982 Rotogran International Inc. has manufactured
granulators and close loop granulating systems
for the plastics and recycling industries. Our modern
facility manufactures innovative equipment that is
durable, dependable and cost efficient. We design and
manufacture granulators and shredders for the plastic
and recycling industry, including granulators from 5
hp to 500 hp, evacuation systems, dust separators,
surge bins with airlocks and metal detecting conveyors.
Rotogran International Inc. is the size reduction
specialist for the processing and recycling industry. In
use around the world, Rotogran granulating systems
are the workhorse of the breed...out-performing and
out-lasting all others in the marketplace today.
TEMPERATURE CONTROLS
SINGLE Temperature Controls, Inc.
2915 Whitehall Park Dr., Suite 700
Charlotte, NC 28273 United States
704-588-5408; 704-588-5813 (fax)
m.bloomhuff@single-temp.com
www.single-temp.com
The development and production of high-performance
and energy-efficient temperature control
systems is the core competency of SINGLE Temperature
Controls, Inc. Our customers benefit
from our expertise that is based on over 40 years
of experience. In addition to standard temperature
control systems and chillers, SINGLE has pioneered
the development of the STWS alternating
temperature system that operates heat/cool water
up to 400 degrees Fahrenheit with individual temperature
control for each circuit to improve component
quality and reduce production time.
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44 JULY/AUGUST 2009 • MODERN PLASTICS WORLDWIDE mpw.plasticstoday.com

THERMAL ANALYSIS,
ANALYZING & TESTING
Netzsch Instruments Inc.
37 North Ave.
Burlington, MA 01803 United States
781-272-5353; 781-272-5225 (fax)
NIB-Sales@netzsch.com
www.e-thermal.com
Netzsch offers thermal analysis & thermal properties
instruments plus contract testing services;
DSC, DTA, TGA, STA (Simultaneous TGA-DSC/
DTA), high accuracy specific heat, coupling to
FTIR & MS to analyze off-gases, DMA, DEA for
thermoset cure monitoring, TMA, Thermal Conductivity,
Thermal Diffusivity by Laser Flash,
Dilatometry for CTE, and Adiabatic Calorimeters
(ARC) to assess thermal hazards and optimize process
safety. We also offer a fully equipped testing
services lab in Burlington, MA.
WELDING/SEALING/
BONDING EQUIPMENT
bielomatik inc.
55397 Lyon Industrial Dr.
New Hudson, MI 48165 United States
248-446-9910; 248-446-6244 (fax)
weldinfo@bielomatikinc.com
www.bielomatikinc.com
Plastic welding:
• Hot plate welding machines.
• Vibration welding machines.
• Laser welding machines.
• Ultrasonic special welding machines, integrated
solutions in combination with other welding processes.
• Complete automation lines with component
handling (fuel tanks, instrument panels, rear
lamps, batteries).
• Tooling and advice on process technology.
• Finishing systems-chipless boring, punching, fly
cutting, machining of plastic parts.
• Prototype welding services.
mpw.plasticstoday.com
Dukane-Intelligent Assembly
Solutions
2900 Dukane Dr.
St. Charles, IL 60174 United States
630-797-4900; 630-797-4949 (fax)
usintl@dukcorp.com
www.dukcorp.com/us
Dukane is a global provider of plastic assembly
systems for the welding of thermoplastic materials.
A standard line of ultrasonic, vibration, hot plate,
spin welders, laser welders and thermal presses are
used to provide solutions that meet the unique
requirements of each customers application. The
line also includes film and fabric sewing and slitting
machines and custom automated assembly
systems. Dukane provides knowledgeable application
engineers, no charge consultations, regional
technical centers and a network of international
offices. Dukane offers a technical training program
and unparalleled Service and Support. Visit
us at our website at www.dukcorp.com/us to find
your local sales representative.
EMC2 Inc.
6855 19 Mile Rd.
Sterling Heights, MI 48314 United States
586-254-1525; 586-254-6649 (fax)
bill@emcsquared.com
www.emcsquared.com
EMC2 Inc. has been a leader in the adhesive bonding
industry for 30 years. Our business has grown from
supplying single dispensing units to the design, build,
and installation of large turnkey automated assembly
lines. These utilize both hot air and RF bond cure
systems. In addition we are the world leaders in inmold
coating systems and press leveling systems, dating
back to 1978. Check out our website for more
details.
Herrmann Ultrasonics, Inc.
1261 Hardt Circle
Bartlett, IL 60103 United States
630-626-1626; 630-626-1627 (fax)
info@herrmannultrasonics.com
www.herrmannultrasonics.com
Herrmann Ultrasonics is The Recognized Technology
Leader and a manufacturer of state-of-the-art
CNC ultrasonic welders for the joining of thermoplastic
parts, fabric and thin films. Systems are
available in 20 kHz, 30 kHz, and 35 kHz with 600-
5000 watt configurations. Proven digital technology
provides precise control of the welding process and
ensures high-strength joints with repeated precision.
Accurate yet robust actuator designs incorporate proportional
valve regulation and variable force control
Winding equipment
for repeatability and reliability. The DIALOG and
new introduced HiQ evolution welder include sophisticated,
easy-to-use operating interface and incorporated
calibration procedure for easy validation
to meet FDA certification.
WINDING EQUIPMENT
Parkinson Technologies Inc.,
Marshall and Williams Plastics
100 Goldstein Dr.
Highland industrial Park
Woonsocket, RI 02895 United States
401-762-2100; 401-762-2295 (fax)
info@parkinsontechnologies.com
www.parkinsontechnologies.com
Parkinson Technologies is an industry leader in
the design and manufacturing of web processing
machinery for the plastics, nonwovens, paper and
specialty materials industries. Product brands include
PARKINSON winders, DUSENBERY converting
systems, MARSHALL & WILLIAMS orientation
lines and KEY FILTERS extrusion melt
filtration equipment. With a broad range of winders,
unwinds, slitter/rewinders, plastics film lines
and orientation systems, Parkinson continues to
set industry standards for machinery innovation
and performance. Parkinson also offers the most
complete plastics extrusion and orientation facility
commercially available for customer use. All
operations and services are located at Parkinson’s
headquarters in Woonsocket, Rhode Island, USA.
Need to stay on the cutting
edge of technology?
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on our home page
to sign up.
MODERN PLASTICS WORLDWIDE • JULY/AUGUST 2009 45

CLASSIFIED ADVERTISING
For information Contact: Cheryl Ackerman (516) 496-8891 • Fax (516) 496-8762 • cheryl.ackerman@cancom.com
Machinery for Sale/Wanted
WWW.TIMBERLINEMACHINERY.COM
$2,000,000 Inventory
Injection Molders
Blow Molders
Extruders
Call Ed Makepeace
Ph: 603-889-7233 (USA) tmi@timberlinemachinery.com
Fax: 603-889-7300 (USA) 100 MACHINES IN STOCK
Buying and Selling Quality,
Used Plastics Machinery
www.hunterplastics.com
100 Pratts Junction Rd., Sterling, MA 01564
Ph: 978-422-8222
Fax: 978-422-8223
Custom Core Pins
Custom Core Pins
AY-MAC PRECISION, INC.
679 Academy Ct. Windsor, CO 80550
Ph (970) 674-1661 Fax (970) 674-1811
email: aymacprecision@aol.com
“The Core Pin Specialists”
Nozzles
Auxiliary Equipment
America’s Largest
Stocking Dealer
Ph: 954-255-6900
Fax: 954-255-5611
sales@machinerycenter.com
Injection Molding/ Blow Molding/Extruders/Auxiliary
If we don’t have it, we’ll find it!!
www.machinerycenter.com
46 JULY/AUGUST 2009 • MODERN PLASTICS WORLDWIDE mpw.plasticstoday.com

CLASSIFIED ADVERTISING
For information Contact: Cheryl Ackerman (516) 496-8891 • Fax (516) 496-8762 • cheryl.ackerman@cancom.com
mpw.plasticstoday.com
Granulator Knives
LOOKING TO PROMOTE YOUR AUCTION??
Too late to run in the magazine?
Why not try our website?
www.plasticstoday.com/mpw
Your Portal to the Plastics Universe.
You can promote your auction for a month at
a low out of pocket cost. Very quick turnaround
time. Usually within 24-48 hours we can get your
auction ad on our website.
Contact: Cheryl Ackerman
cheryl.ackerman@cancom.com
Phone: 516-496-8891
Moldflow Analysis
Consulting
Custom Services
Allgrind Plastics
CUSTOM GRINDING
• PULVERIZING
• GRANULATION
• CRYOGENIC PULVERIZING
• SIFTING/BLENDING
N.J.: 908/479-4400
www.allgrind.com info@allgrind.com
Materials for
Sale/Wanted
C O N T A M I N A T E D
DON’T DUMP, WE CAN USE
Also need clean cellulosics, Acrylics,
Polycarbonates or wide range of plastic scrap
ENTIS ASSOCIATES
1600 Beacon St. Suite 506, Brookline, MA 02246
Tel: 617 267 2322 Fax: 617 277 9493
Cylinder Engraving
Jacobsen Lenticular Tool & Cylinder
Engraving Technologies (JacoTech)
• Lenticular Design & Cylinder Engraving •
Cylindrical Extrusion/Embossing/Casting
Plastic Processing Moulds • Optical Moulds:
Lens Arrays for Solar Concentrators,
Display, Security, Illumination, Diffusers,
Reflective, Decorative, etc • Lenses,
Prisms, V-Grooves, 4-Side Pyramids,
Concave/Convex, Faux, etc. • 1-5 Multi Axis
CNC Diamond Turn/Mill – 42” OD x 177”
Email: GJ@JacoTech.com /www.JacoTech.com
Phone: 630-467-0900 / Fax: 630-467-0901
105 E. Irving Park Rd. Itasca, Illinois 60143 USA
MODERN PLASTICS WORLDWIDE • JULY/AUGUST 2009 47

CLASSIFIED ADVERTISING
For information Contact: Cheryl Ackerman (516) 496-8891 • Fax (516) 496-8762 • cheryl.ackerman@cancom.com
Hot Runners
Purging Compounds
ULTRA PURGE!
RECOMMENDED BY HUSKY INJECTION MOLDING SYSTEMS
Save time and reduce scrap during color
changes without stopping your production.
Benefits:
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- Formulation for Every Application or
General Purpose Grade
Ultra Purge cleans:
• Screws
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Use with:
• Injection Molding Machines
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Ask about our NEW
“COLOR CHANGE ON THE FLY” TECHNOLOGY!
For more information or a FREE SAMPLE,
call 714-708-2663 or visit www.ultrapurge.com
Professional Services
TIME-CRITICAL CONFIDENTIAL
PROBLEM SOLVING SINCE 1973
• CHEMICAL ANALYSES
AND CHARACTERIZATION
• THERMAL ANALYSIS AND RHEOLOGY
• MECHANICAL TESTING
• ORGANIC SYNTHESIS
• LAB COMPOUNDING, PELLETIZING
AND INJECTION MOLDING
• FAILURE ANALYSIS
• QUALITY ASSURANCE
• CHEMICAL RESISTANCE
• ACCELERATED WEATHERING
• FDA EXTRACTIONS
Recruitment
48 JULY/AUGUST 2009 • MODERN PLASTICS WORLDWIDE mpw.plasticstoday.com
• R & D
LABORATORIES, INC.
http://www.polyhedronlab.com
®
• PLASTICS
• POLYMERS
• RUBBER
• ASTM
281-879-8600
FAX281-879-8666
10626 KINGHURST
HOUSTON, TX 77099
Polymer Analysis Services
Deformulation
Contaminant Identification
Polymer Characterization
Failure Analysis
Physical/Material Testing
Litigation Support
800.659.7659
www.chemir.com
PLASTIC PLACEMENT NATIONWIDE
Specializing in the Compounding and
Colorants Industries Since 1978
plasticsjobsearch.com
All inquiries handled in confidence
Fees paid by employer
JOHN ANDERSON & ASSOCIATES
ph: 817-514-1920 fx: 817-514-1922
email: johnanderson-assoc@airmail.net
Modern Plastics Worldwide is the place
to advertise. Our readership combined
with our editorial excellence makes us the
number one choice. We reach more
people in the plastics industry than any
other plastics publication, worldwide
Contact: Cheryl Ackerman
(516) 496 8891
cheryl.ackerman@cancom.com

CALENDAR OF EVENTS
SEPTEMBER
13-15 AMBA Fall Conference 2009, Washington DC.
American Mold Builders Association
Tel: +1 847-222-9402; Fax: +1 847-222-9437
info@amba.org; www.amba.org
14-17 FOAMS 2009, Iselin, NJ
Society of Plastics Engineers
Tel: +1 203-740-5403; Fax: +1 203-775-8490
conferences@4spe.org; www.4spe.org/
15-16 Medical Grade Polymers 2009, Philadelphia
Applied Market Information LLC. Contact: Margit Korsak
Tel: +1 610-478-0800; +1 610-478-0900
mk@amiplastics-na.com; www.amiplastics-na.com/Events
21-22 SpecPlast 2009, Zurich, Switzerland.
Maack Business Services. Contact: Sylvia Probst
Tel: +1 41 44-781-3040; Fax: +1 41 44-781-1569
mbspolymer@bluewin.ch; www.mbspolymer.com
21-24 MD&M Midwest, National Mfg. Week, Quality Expo, Green
Manufacturing, Plastics USA, Plastec 2009, Rosemont, IL
Canon Communications LLC
Tel: +1 310-445-4200; Fax: +1 310-996-9499
www.canontradeshows.com
22-24 Sustainable Packaging Forum 2009, Atlanta, GA.
Packaging Strategies. Contact: Karen Close
Tel: +1 610-935-2183
meetings@packstrat.com; http://www.bnpevents.com/
23-24 Medtec Ireland 2009, Galway.
Canon Communications LLC
Tel: +353 1-806-0557; Fax: +353 1-862-1482
medtecireland@cancom.com; www.canontradeshows.com
23-26 Tiprex/Pack Print International 2009. Bangkok.
Messe Düsseldorf Asia
Tel: +1 312-781-5180; Fax: +1 312-781-5188
info@mdna.com; www.mdna.com
28-10/1 Plastics Industry Show, Moscow.
Maxima JSC. Contact: Alina Vorontsova
Tel: +749 9124-7760; Fax: +749 9124-7060
vorontsova@maxima-expo.ru; www.maxima-expo.ru/eng
29-10/3 SPE Eurotec Conference, Marne la Vallee, France.
Society of Plastics Engineers. Contact: Lesley Kyle
Tel:+1 203-740-5452
lskyle@4spe.org; www.4spe.org/spe-eurotec-conference
OCTOBER
4-7 NRC Annual Congress & Expo 2009, Portland, OR.
National Recycling Coalition Inc.
Tel: +1 202-789-1430; Fax: +1 202-789-1431
info@nrc-recycle.org; www.nrc-recycle.org
5-7 API Polyurethanes Technical Conference 2009, Ft Washington, MD.
Alliance for the Polyurethanes Industry
Tel: +1 703-741-5103; Fax: +1 703-741-5655
www.polyurethane.org
5-7 Pack Expo/Process/Converting & Package Printing Expo
2009, Las Vegas. Packaging Machinery Manufacturers Institute.
Tel: +1 703-243-8555; Fax: +1 703-243-3038
expo@pmmi.org; www.packexpo.com
7-8 SPI Film & Bag Federation Fall Conference 2009, Las Vegas.
Society of the Plastics Industry, Film and Bag Federation
Contact: Natha Freiburg
Tel: +1 202-974-5218; Fax: +1 202-296-7675
nfreiburg@plasticsindustry.org; www.plasticbag.com
13-15 PEPP 2009 Polyethylene Polypropylene Chain, Zurich.
Maack Business Services MBS. Contact: Sylvia Probst
Tel: +41 44-781-3040; Fax +41 44-781-1569
mbspolymer@bluewin.ch; www.mbspolymer.com
13-17 Fakuma 2010, Friedrichshafen, Germany.
P.E. Schall GmbH & Co. KG
Tel: +49 7025-920-60; +49 7025-920-6620
info@schall-messen.de; www.fakuma-messe.de/en/fakuma
20-22 Medical Design & Manufacturing Minneapolis/MidPak,
Minneapolis, MN. Canon Communications LLC.
Tel: +1 310-445-4200; Fax: +1 310-996-9499
www.canontradeshows.com
21-22 MassPlastics ‘09, Fitchburg, MA.
North Central Massachusetts Chamber of Commerce
Contact: Bud Arbo
Tel: +1 978-353-7600, ext. 242
bud@massplastics.com; www.massplastics.com
29 Plastics Industry Strategy Seminar 2009, Houston
Applied Market Information LLC
Contact: Whitney Gallagher
Tel: +1 610-478-0800; Fax: +1 610-478-0900
wg@amiplastics-na.com; www.amiplastics-na.com
mpw.plasticstoday.com
ADVERTISER INDEX
COMPANY PAGE
Absolute Machinery Corporation 36
Arburg GmbH + Co. KG 3
Canon Communications LLC Trade Events 29
CMAI (Chemical Market Associates Inc.) 27
CROWN Machine uwp Inc. 39
En Chuan Chemical Industries Co. Ltd. 8
ExxonMobil Chemical 33, 51
Hosokawa Alpine 52
Lurgi 7
Maack Business Services 37
PCC Chemax 35
PerkinElmer 17
Plastics Today 33
Sinopec Catalyst Company 2
Society of Plastics Engineers, Automotive Division 23
Tria 19
Univar USA 4
WEIMA America Inc. 13
Xaloy 52
MODERN PLASTICS WORLDWIDE
UPCOMING DIRECTORIES
PRIMARY PROCESSING
MACHINERY DIRECTORY
December 2009
Contact Iris Topel
Tel: +1 718-478-8104
Fax: +1 718-478-8105
iris.topel@cancom.com
Tech Bulletins and e-Weekly:
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MODERN PLASTICS WORLDWIDE (ISSN 0026-8275) is published monthly, except July/August, with an
additional issue in summer, by Canon Communications LLC, 11444 W Olympic Blvd., Los Angeles, CA
90064-1549. Periodicals postage paid at Los Angeles, CA, and at additional mailing offices. Canada Post
International Publications Mail Product Sales Agreement No. 40612608. Canada Post return address:
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Modern Plastics Worldwide has no connection with any company of similar name. The name ‘Modern Plastics’
is Registered ® U.S. Patent Office. Copyright © 2004 Canon Communications LLC. All rights reserved. Printed
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MODERN PLASTICS WORLDWIDE • JULY/AUGUST 2009 49

SPOTLIGHT
WITH C&J INDUSTRIES
Dennis Frampton touts
innovation, training, and
continuous improvement.
Some of the 250 staff members have
indeed been active at the company for
the last 30 years, says Dennis Frampton,
company president. Investing in
staff means paying tuition for continuing
education (the company budgets
about $100,000/yr for in-plant seminars
and tuition), something Frampton says
is a given at his company but amazingly
not at many other molders and
tool builders throughout the country.
“Everybody in our sector is searching
for good staff, but they’re not creating
them themselves,” he says. The
company’s founder, Dick Johnston,
who died in 2007, so believed in his
employees that he gave 49% of the
company to them, leaving the rest to
the immediate family, including sonin-law
Frampton.
“My father-in-law was grateful for
what the staff did for the company
because our success to a large part is due
to employee loyalty and involvement,” he
says. The company started in a two-car
garage in 1962 as a mold builder called
Meadville Precision Tool and Mold. By
the end of the first decade it had grown to
10 employees. Today it turns out between
75-100 molds/yr, mainly produced on
50 JULY/AUGUST 2009 • MODERN PLASTICS WORLDWIDE mpw.plasticstoday.com
West
Buffalo
Meadville
Pittsburgh
Clarksburg
Pennsylvania
Philadelph
MD
Ba
Wa
Plastics contract molder and product
designer C&J Industries (Meadville, PA)
reckons investing in its employees is its
best opportunity to ensure a healthy future.
high-speed milling
machines that
reduce the delivery
times to customers
versus that which
spark erosion and
polishing processes
previously dictated.
Frampton says the company rather
fell into injection molding during the
1970s by acquiring two used presses
because one of its tooling customers
wanted the mold builder to qualify
molds prior to shipment, but C&J didn’t
have presses. “One of the best things to
ever happen to C&J was that we got out
of molding for the automotive sector and
concentrated on precision applications
for medical device, electrical/electronics,
and telecommunication sectors,” he says.
One high profile but low volume customer
is Segway, maker of the personal
transporter.
Frampton also credits high use of
automation and a movement toward
more cleanroom molding as helping to
sustain business, with the company adding
cleanroom processing in the early
1980s. He proudly points to a complex
64-cavity medical cap mold the company
designed and is using to supply the pharmaceutical
sector (see photo, above).
Today the company has 48 presses ranging
from 22-720 tonnes clamping force,
almost exclusively Toshiba electrics.
C&J has plans to replace all its presses
by 2015 in order to maintain its level of
Meadville, PA
technology. Frampton also says during
the 1990s C&J noticed how many customers
reduced their engineering staffs,
so the molder sagely decided to offer
product design as a service.
C&J holds monthly improvement
meetings to hone the company’s procedures.
One success Frampton points to
was simply to move the tool building,
which was located three miles away, to
the molding and design operations. “We
were able to reduce scrap by 80% due
to better communications between engineers
and tool makers,” he says. Another
improvement was the creation of separate
incoming and outgoing warehousing
facilities to avoid any possible mix-ups
that could affect its medical device business.
The company has also taken on the
responsibility of JIT parts delivery via the
Internet to oversee customers’ inventory
and relieve the client of such work.
Frampton decided in 1967 to follow
the footsteps of his father, who worked
as a mold builder at the company, by
applying for a die apprenticeship. Working
full time and attending university
in the evenings to obtain his bachelor
degree kept him busy outside and within
company operations, where he also met
his soon-to-be wife, Diann, an art student
who was working at her father’s
company. Frampton worked his way up
the ladder while they raised their family,
eventually becoming president.
Robert Colvin • robert.colvin@cancom.com

Teach polypropylene cool new tricks.
With Vistamaxx elastomers as a blend partner, polypropylene can perform in a whole new way.
Vistamaxx specialty elastomers let you demand more from existing polypropylene applications – and might even lead you to
new ones. This versatile portfolio of products can improve strength, softness, flexibility and clarity. Because they’re halogen-free
and lighter weight, Vistamaxx specialty elastomer / polypropylene blends may be an effective alternative in PVC applications.
How cool would that be? Fetch more information on gomaxxgo.com.
Vistamaxx specialty elastomers Maxximize Peformance
©2009 Exxon Mobil Corporation. The terms corporation, ExxonMobil, ExxonMobil Chemical, our and its, as used in this advertisement, sometimes refer not only to ExxonMobil Chemical Company,
a division of Exxon Mobil Corporation, but collectively to all of the companies affiliated with Exxon Mobil Corporation or to any one or more of them or their employees. Photos used in this ad may be representative of potential product applications only.
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FOR IMPROVED PERFORMANCE
AND PRODUCT QUALITY
CHOOSE XALOY
Building on our leadership in high-performance screws,
barrels and other key components, Xaloy helps machinery
OEMs and plastics processors reduce costs and improve
productivity by OPTIMIZING THEIR PROCESS.
Barrels: The leader in development of
improved alloys and production processes
NEW nXheat Induction Barrel Heating: Sharply
cuts energy costs and improves temperature control
Performance Screws: Manufactured using a
range of base materials, hardsurfacing alloys and
full-length treatments
Nozzles: Engineered to work, built to last. Front
end components include Shutoff Nozzles, non return
valves, nozzles, tips & end caps
Screen Changers: With 55 years of experience,
innovation and development of filtration systems
Xaloy offers manual, hydraulic and continuous
models proven in a wide variety of applications
Melt Pumps: Efficiently meters polymer output for
higher product quality, and significant materials savings
Rolls: Chill and heat transfer rolls are built to
perform and last with unique patented construction
Pelletizers: Rheologically optimized design offers
consistently uniform pellets
Jet Cleaners: Designed to remove all types
of thermoplastic and thermoset compounds in
a safe, efficient manner
Molders and extruders worldwide reap the
benefits of Xaloy products in their operations.
Visit www.xaloy.com for more information.
www.xaloy.com every pellet knows our name
EXTRUSION • INJECTION • E U R O P E • A S I A • J A P A N
800-457-7550 800-816-7711 +49 (0)7132-99935-17 +66 (38) 717 084 +81-45-661-3508
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For Zebras stripes are part of the package
With the new Generation X Die Head Technology they
are not. This innovative high technology Die Head Series
offers:
· Film free of Portlines
· Up to 50% reduction in purging time
· Up to 9 layers
· Rapid Change-over
Hosokawa Alpine Blown Film Lines –
Quality made in Germany.
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PROCESS TECHNOLOGIES FOR TOMORROW
HOSOKAWA
ALPINE Aktiengesellschaft
Peter-Dörfler-Straße 13 – 25
D – 86199 Augsburg, Germany
Tel.: +49(0)821/59 06-124
Fax: +49(0)821/59 06-600
plastics@alpine.hosokawa.com
www.alpinehosokawa.com